Doosan DX300LCA. Operation and Maintenance Manual (2010)

Check Engine Fan Belt Tension

FAN

10mm/10kg

COMPRESSOR

IMPORTANT

A loose fan belt can cause engine overheating, poor

ALTERNATOR

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

can cause damage to the water pump, alternator bearing or

belt.

CRANKSHAFT

FG000353

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

Figure 44

operation.)

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

by pressing downwards on the belt, midway between the

fan pulley and alternator pulley. The belt should flex

approximately 10 mm (0.4 in). See Figure 44. To adjust the

belt, loosen the alternator adjustment plate bolts, adjust the

belt tension and retighten the bolts.

Inspection, Maintenance and Adjustment

OP001005

4-29

Check Engine Fan Belt Wear

WARNING

Keep clear of engine fan and fan drive belts when the

engine is running. Rotating fan and belt contact can cause

injury.

Figure 45

WARNING

When checking, adjusting or replacing drive belts, care

must be taken to prevent accidental cranking of the engine.

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

controls are tagged.

Replace badly worn, greasy or severely cracked belts

immediately. These conditions prevent proper belt

function. Visually inspect the belt. Check the belt for

intersecting cracks. Transverse

(across the belt width)

cracks are acceptable. Longitudinal

(direction of belt

length) cracks that intersect with transverse cracks are not

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

material missing.

Before installing new belts, make sure all pulley grooves

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

the grooves are worn.

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

working order.

When replacing belts and pulleys, pulley alignment must

be checked with belts tensioned and brackets securely

clamped. A misalignment that can be detected by the

naked eye is detrimental to belt performance.

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

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

cords which will cause the belts to turn and result in

complete destruction of the belts in operation.

Belts on new machines and replacement belts lose their

tension as they seat into the pulley grooves. Check the

tension of new belts at 50 hour intervals until tension is

stabilized and thereafter, every 250 hours. If the tension

falls below the required minimum, the belt slips damaging

the belts and pulley grooves.

NOTE: When operating in abrasive conditions, check

tension every 100 hours.

Inspection, Maintenance and Adjustment

OP001005

4-30

Check Oil Level in Travel Reduction

Device (One on Each Side of Unit)

WARNING

The gear oil is very hot after the machine has been

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

Before fully removing any motor case inspection port plug,

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

FG000298

escape.

Figure 46

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

Rotate the track until ports (1 thru 3, Figure 46) are in their

proper positions as shown.

Loosen fill plug (3, Figure 46) slightly to allow pressurized

air to escape.

Remove oil level plug (1, Figure 46).

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

level plug opening.

Add oil through the fill plug

(3, Figure

46) opening, if

necessary.

Clean and install oil level and fill plugs (1 and 3, Figure 46).

Repeat this procedure on the other travel reduction device.

Inspection, Maintenance and Adjustment

OP001005

4-31

Change Breaker Filter Element (Optional)

WARNING

The hydraulic oil will be hot after normal machine

operation.

Allow the system to cool down before changing pilot filter.

FG000339

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

attachment to the ground and shut down engine.

Figure 47

Loosen the hydraulic oil tank breather cap to release

pressure.

Locate breaker filter assembly (Figure 47).

Position a container under the filter assembly. Remove the

drain plug and completely drain the assembly.

Using a 30 mm spanner, unscrew filter housing from filter

bottom.

Remove O-ring from filter head.

Replace filter.

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

install the filter housing on the filter head.

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

Install drain plug in bottom of filter housing.

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

level of hydraulic oil tank.

Change Swing Reduction Device Oil (Drain

and Refill After First 250 Hours)

NOTE: Change swing reduction device oil after first

250

hours on a new machine and every 2,000 hours

thereafter (See page 4-49).

Change Oil in Travel Reduction Device

(One on Each Side of Unit) (After First

250 Hours)

NOTE: Drain and refill oil after first 250 hours of operation or

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

4-46).

Inspection, Maintenance and Adjustment

OP001005

4-32

Change Engine Oil and Filter

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

operation or rebuild, then every 500 thereafter.

WARNING

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

cool down before attempting to change the engine oil and

filter to avoid burns by touching hot engine parts.

Position a larger container under the engine. Remove cap

(1, Figure 48) and install hose (2) to drain the engine oil.

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

NOTE: Dispose of drained fluids according to local

regulations.

FG000144

Figure 48

Replace engine oil filter by using filter wrench. The engine

oil filter is a spin-on type. See Figure 49. Remove and

discard filter.

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

gasket. Screw filter on head until gasket contacts head,

turn filter 1/2 turn more.

FG015482

Figure 49

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

(Figure 50). Refer to the Lubrication Table of this manual

for the recommended oil for the operating conditions.

NOTE: See

“Fluid Capacities” on page 4-8. for

capacity.

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

and check engine oil pressure light.

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

oil level after fifteen minutes.

FG015483

Figure 50

Inspection, Maintenance and Adjustment

OP001005

4-33

Replace Hydraulic Oil Return Filter (After

First 250 Hours)

NOTE: Replace hydraulic oil return filter after first 250 hours

of operation or rebuild, then every

1,000 hours

thereafter (See page 4-44).

Change Pilot Filter (After First 250 Hours)

NOTE: Change pilot filter after first 250 hours and every

1,000 hours thereafter (See page 4-45).

Inspect Pins and Bushings of the Front

End Attachments for Signs of Wear

Check Fluid Levels in Batteries and

Battery Charge Levels

Inspect for Any Loose or Missing Nuts and

Bolts

Inspect Fuel System Hose Clamps

Inspection, Maintenance and Adjustment

OP001005

4-34

500 HOUR / 3 MONTH SERVICE

Perform All Daily, 50 and 250 Hour Service

Checks

Grease Swing Gear and Pinion

WARNING

Greasing swing gear and pinion must be serviced by only

one person.

Remove inspection cover and inspect the condition of the

grease. Make sure that water or other contaminants are

not noticeable.

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

time so that the entire face of the swing gear

can be lubricated. Use extreme caution when

performing this operation.

FG000147

Figure 51

If water or other contaminations are found, remove the

lower access cover so that the gear teeth can be

thoroughly cleaned and lubricated.

Install access covers after lubricating gear teeth.

FG000148

Figure 52

Inspection, Maintenance and Adjustment

OP001005

4-35

Clean Air-Conditioning Outer Filter

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

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

cabin. This filter should be cleaned out.

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

environment, the cleaning and replacement should

be performed more frequently. If filter is damaged,

replace damaged filter with a new one.

WARNING

All service and inspection of air-conditioning system should

be performed with the starter switch in the "O" (OFF) position.

WARNING

If using compressed air to clean the element, make sure

that proper eye protection is worn.

Donaldson.

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

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

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

FG000440

the cover (1, Figure 53) by loosening the four wing bolts.

Figure 53

Open the cover by turning the knob (1, Figure 54) in the

rear of the cabin.

FG000441

Figure 54

Remove filter (Figure 55) and inspect for any damage.

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

change to new one.

Reassemble in reverse order.

FG000342

Figure 55

Inspection, Maintenance and Adjustment

OP001005

4-36

Check and Clean Air-Conditioning Inner

Filter

WARNING

All service and inspection of air-conditioning system

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

(OFF) position.

WARNING

If using compressed air to clean the element, make sure

that proper eye protection is worn.

FG000422

Remove the filter by pulling out ward the knob while

Figure 56

pressing the upper part and lower part of the filter handle

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

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

damaged replaced by a new one.

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

water to clean it.

IMPORTANT

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

completely dry before installing.

Inspection, Maintenance and Adjustment

OP001005

4-37

Clean Radiator, Oil Cooler, Intercooler,

Fuel Cooler and Air Conditioner

Condenser Core

WARNING

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

there is danger of injury. Always wear protective glasses,

FG000150

mask and safety shoes during the cleaning precess. Make

Figure 57

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

Open the rear left door and engine cover.

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

of oil cooler and intercooler.

FG000151

Figure 58

Remove wing bolts and plate (Figure 59) between radiator

and oil cooler.

Clean the outside of the radiator and oil cooler, intercooler

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

from the outside of the engine compartment inwards.

Repeat the cleaning process from the inside of the engine

compartment outwards to remove all dirt and debris.

NOTE: Clean dust net and install it after cleaning

radiator, oil cooler, intercooler and fuel cooler.

FG000152

Figure 59

Clean air conditioner condenser core with compressed air,

steam or water.

IMPORTANT

To prevent damage to the cores, apply compressed air

from an appropriated distance. Damaged core may

cause water leakage or overheating. In a dusty site,

check the core daily, irrespective of the maintenance

interval.

FG000153

Figure 60

Inspection, Maintenance and Adjustment

OP001005

4-38

Clean Outer Filter of Air Cleaner

02/05 [MO] 11:30

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

service.

NOTE: If air cleaner clogged warning light (Figure 61) on

instrument panel comes "ON" the air cleaner must be

serviced.

NOTE: When working in severely dusty conditions, the

service interval should be shortened.

E/G SPEED 1700 RPM

FG000264

Figure 61

WARNING

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

engine is running.

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

proper eye protection is worn.

Locate the air cleaner assembly.

NOTE: When it reaches every 500 hours or If indicator

light

(Figure

61) on instrument panel comes

"ON" the air cleaner must be serviced.

NOTE: Replace outer filter after cleaning 5 times or

every 2,000 hours / 1 year of service.

Remove and clean rubber evacuator valve (1, Figure 62)

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

lips for wear or damage. Replace valve if necessary.

FG000297

NOTE: Install evacuator valve with lips parallel to the

Figure 62

cover.

Remove the access cover (2, Figure 63) by loosening the

latches (3).

Remove the outer filter (4, Figure 63) from the housing. Do

not remove inner filter (5).

FG000702

Figure 63

Inspection, Maintenance and Adjustment

OP001005

4-39

Clean the outer filter (4, Figure 63) by blowing compressed

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

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

HAOC570L

Figure 64

Check outer filter by shinning a light through it. If small

holes or thinner parts are found on the element after

cleaning it, replace the filter.

Clean the inside of the air cleaner body and the inside of

the air cleaner cover. Do not use compressed air.

Properly install the air filter and cover.

After filter service be sure to install cover with arrows

pointing "UP."

NOTE: If after cleaning the outer filter, the air cleaner

FG000412

clogged indicator remains "ON," replace the

Figure 65

outer and inner filters. Do not clean inner filter.

Inspection, Maintenance and Adjustment

OP001005

4-40

Change of Fuel Prefilter

Open the left rear side door to access fuel prefilter.

Position a small container under prefilter. Drain fuel by

opening drain valve on bottom of filter.

NOTE: Dispose of drained fluids according to local

regulations.

FG015484

Figure 66

Remove the bowl using supplied tool.

Remove the cartridge.

FG015485

Figure 67

Coat surface of packing (2, Figure 68) with fuel on new

cartridge (1).

Tighten the cartridge by hand until the packing comes into

contact with the surface of the filter housing head.

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

of a turn more.

Coat surface of seal (3, Figure 68) with fuel, and tighten

the bowl with tool.

FG000428

Figure 68

Inspection, Maintenance and Adjustment

OP001005

4-41

Change Fuel Filter

WARNING

Exchange filter after waiting for engine to cool. Be careful of

fire hazards. Do not smoke.

Locate fuel filter inside engine compartment.

FG000154

Position a small container under fuel filter.

Figure 69

Unscrew fuel filter from head assembly. Discard fuel filter.

NOTE: Dispose of drained fluids according to local

regulations.

After cleaning filter head, install new fuel filter. Screw filter

on head until gasket contacts head, and turn filter 1/2 turn

more with a filter wrench.

NOTE: Coat fuel filter gasket with fuel.

NOTE: Fill fuel filter with clean fuel. This will help

reduce fuel system priming.

FG000478

Figure 70

Fuel System Priming

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

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

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

engine speeds.

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

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

procedure:

Shut down engine.

FG000431

Loosen plug (1, Figure 71) on the fuel prefilter head.

Figure 71

Pump the hand operated primer pump (2, Figure 71) on the

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

in fuel prefilter head.

Tighten plug (1, Figure 71) in fuel prefilter head.

Continue to pump primer pump until a strong resistance is

felt.

Start engine and look for signs of leaks.

Repeat procedure if necessary.

Inspection, Maintenance and Adjustment

OP001005

4-42

1,000 HOUR / 6 MONTH SERVICE

Perform All Daily, 50, 250 and 500 Hour

Service Checks

Grease Swing Reduction Device

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

attachment to the ground and shut down engine.

Remove air vent plug (1, Figure 72) from swing reduction

device.

FG000439

Figure 72

Press grease fitting and inject grease with the grease gun

on the marked point (2, Figure 73).

Install air vent plug

(1, Figure

72) in swing reduction

device.

FG000156

Figure 73

Inspection, Maintenance and Adjustment

OP001005

4-43

Replace Hydraulic Oil Return Filter

02/05 [MO] 11:30

NOTE: Change hydraulic oil return filter after first 250 hours

of operation or rebuild, and every

1,000 hours

thereafter.

NOTE: If return filter clogged warning light (Figure 74) on

instrument panel comes "ON" the return filter must be

serviced.

E/G SPEED 1700 RPM

FG000760

Figure 74

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 hydraulic

breather cap slightly to allow the pressurized air to vent.

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

either the fill cap or service covers or drain water from the

FG000424

tank.

Figure 75

IMPORTANT

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

hydraulic tank, especially around the fill port and filter

ports.

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

attachment to the ground and shut down engine.

Lift the breather cap (1, Figure 75) slightly to release the

internal pressure.

Remove bolts

(2, Figure

75) and service cover

(3).

Remove spring (4), valve

(5) O-ring

(6), and bypass

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

Remove filter and discard.

NOTE: Used filter should always be disposed of

according to local regulations.

FG000761

Figure 76

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

valve and spring. Install service cover plate.

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

circuit.

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

necessary.

Inspection, Maintenance and Adjustment

OP001005

4-44

Change Pilot Filter

02/05 [MO] 11:30

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

rebuild, and every 1,000 hours thereafter.

NOTE: If pilot filter clogged warning light

(Figure

77) on

instrument panel comes "ON" the pilot filter must be

serviced.

E/G SPEED 1700 RPM

FG000763

Figure 77

WARNING

The hydraulic oil will be hot after normal machine

operation.

Allow the system to cool down before changing pilot filter.

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

attachment to the ground and shut down engine.

FG000149

Lift the breather cap (1, Figure 75) slightly to release the

Figure 78

internal pressure.

Locate pilot system filter assembly. See Figure 78.

Unscrew canister (5, Figure 79) and remove O-ring (3) and

filter cartridge (4).

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

when removing this assembly.

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

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

canister assembly onto the filter head (1, Figure 79).

NOTE: Used filter should always be disposed of

according to local regulations.

FG000323

After changing pilot filter, vent air from pump and check

Figure 79

level of hydraulic oil tank.

Inspection, Maintenance and Adjustment

OP001005

4-45

Change Oil in Travel Reduction Device

(One on Each Side of Unit)

WARNING

The gear oil is very hot after the machine has been

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

Before fully removing any motor case, inspection port plug,

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

FG000298

escape.

Figure 80

NOTE: Drain oil after first 250 hours of operation or rebuild,

and every 1,000 hours thereafter.

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

Rotate the track until ports (1 thru 3, Figure 80) are in their

proper positions as shown.

Place a container under drain plug (2, Figure

80) and

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

oil.

NOTE: Dispose of drained fluids according to local

regulations.

Install drain plug (2, Figure 80). Refill the travel reduction

gear case with fluid through fill port (3) until the fluid level is

at port (1). Install level plug (1) and fill plug (3).

NOTE: See

“Fluid Capacities” on page 4-8. for

capacity.

Repeat this procedure on the other travel reduction device.

Change Air Breather Filter

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

attachment to the ground and shut down engine.

Lift the breather cap(2. Figure 81) slightly to release the

internal pressure.

Unscrew the bolt (1, Figure 81) and take off the breather

cap (2, Figure 81).

Change a filter cartridge (3, Figure 81) and assemble the

breather cap by tighting the bolt.

NOTE: Used filter should always be disposed of

according to local regulations.

FG013207

Figure 81

Inspection, Maintenance and Adjustment

OP001005

4-46

Change Air-Conditioning Outer Filter

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

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

cabin. This filter should be cleaned out.

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

environment, the cleaning and replacement should

be performed more frequently. If filter is damaged,

replace damaged filter with a new one.

WARNING

All service and inspection of air-conditioning system

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

Donaldson.

(OFF) position.

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

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

FG000440

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

four wing bolts and washers, and access cover (1, Figure 82).

Figure 82

Open the cover by unscrewing the knob (1, Figure 83) in

the rear of the cabin.

FG000441

Figure 83

Remove filter (Figure 84) and replace with new one.

Reassemble in reverse order.

FG000342

Figure 84

Inspection, Maintenance and Adjustment

OP001005

4-47

Check Air Conditioner Refrigerant

WARNING

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging

air-conditioning system.

Run engine at about 1800 rpm. Operate for a minimum of

FG000157

ten minutes to stabilize the system.

Figure 85

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

Put the temperature control switch in maximum cooling

position.

Press the "Internal Air Circulation" switch.

Compare the flow of bubbles in the sight glass of receiver

dryer with the drawings in the following table.

CAUTION

Overfilling refrigerant may cause dangerous

high-pressure and poor cooling action; and low

refrigerant level may cause compressor damage.

Always maintain refrigerant at normal level.

Amount of

Appearance of the Sight Glass

Solutions

Refrigerant

Almost clear.

Normal

Any bubbles disappear.

Charge or withdraw the system with

the correct amount of HFC-134a

High

No bubbles are seen.

refrigerant.

Low

A flow of bubbles is visible.

Check and Adjust Engine **

Contact your nearest DOOSAN dealer.

Engine dealer for checking and adjusting the following items:

•

Engine Compression Pressure.

•

Injection Pressure.

•

Injection Timing.

Inspection, Maintenance and Adjustment

OP001005

4-48

2,000 HOUR / YEARLY SERVICE

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

Hour Service Checks

Change Swing Reduction Device Oil

NOTE: Change swing reduction device oil after first

250

hours of operation or rebuild and every 2,000 hours

thereafter.

WARNING

The gear oil is very hot after the machine has been

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

FG000133

Figure 86

Set a container under excavator.

Release the drain plug (3, Figure 87) and drain the swing

reduction device oil into a container.

NOTE: Dispose of drained fluids according to local

regulations.

After draining oil, tighten the drain plug.

FG014340

Figure 87

Remove breather/fill cap (2, Figure 86) and add oil to "H"

mark on dipstick (1).

FG000419

Figure 88

Inspection, Maintenance and Adjustment

OP001005

4-49

Replace Outer and Inner Air Cleaner

Elements

WARNING

Never clean or attempt to remove the air cleaner element if

the engine is running.

FG000414

NOTE: Replace outer element after cleaning 5 times or every

2,000 hours of service.

Figure 89

NOTE: Replace inner element whenever a new outer

element is installed.

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

following procedure.

Open the access door at the rear of the cabin.

Remove the evacuator valve (1, Figure 90) and air cleaner

cover (2).

NOTE: Inspect evacuator valve seal lips for wear or

damage. Replace valve if necessary. Install

FG000425

evacuator valve with lips parallel to the cover.

Figure 90

Remove outer filter (4, Figure 90) from the air cleaner

housing.

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

housing.

Remove inner filter (5, Figure 91).

Clean out inside of air cleaner housing. Do not use

compressed air to blow out housing.

Install new inner filter. Do not clean and reuse inner

element.

Install new outer filter.

Install air cleaner cover and evacuator valve.

NOTE: Make sure that all gaskets and cover are

properly installed and seated.

FG000426

Figure 91

Inspection, Maintenance and Adjustment

OP001005

4-50

Change Radiator Coolant

WARNING

Allow the engine to cool before releasing the radiator cap.

Make sure to loosen the cap slowly to release any

remaining pressure.

Radiator cleaning is performed while the engine is running.

Take extreme caution when working on or near a running

ARO1760L

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

Figure 92

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.

CAUTION

Do not mix ethylene glycol and propylene glycol when

changing the antifreeze solution. Flushing should be

performed to minimize volume of mixing between the two

columns. Mixing the two compounds may cause generation

of foreign material to damage the system.

Do not mix antifreeze solutions from different

manufactures. Mixed solution may degrade the capabilities

of the system. It is recommended to use the standard

product from Doosan.

In the bitterly cold area or weather, the customer should

frequently check the performance of the coolant for

appropriateness for the weather, and then determine

change cycle of the coolant.

Slowly open the radiator cap to allow any pressure to

escape.

Place a container under the radiator and open the drain

valve (2, Figure 93).

NOTE: Dispose of drained fluids according to local

regulations.

FG000319

Figure 93

Inspection, Maintenance and Adjustment

OP001005

4-51

Remove coolant drain plug (1, Figure 94) from engine.

Install drain plug, and close drain valve after coolant has

completely drained from system.

Fill cooling system with a flushing solution.

Run engine at low idle until the coolant temperature gauge

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

minutes.

Allow engine to cool.

Drain flushing fluid and fill system with water.

FG000322

Figure 94

Run engine again to allow water to completely circulate.

10. After allowing engine to cool, drain water and fill system

with proper antifreeze mixture for ambient temperature.

Refer to coolant concentration table. See

“Antifreeze

Concentration Tables” on page 4-77.

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

be purged from system. Fill radiator to fill neck.

12. Drain and fill radiator coolant recovery tank.

Inspection, Maintenance and Adjustment

OP001005

4-52

Hydraulic Oil Exchange and Suction

Strainer Cleaning

WARNING

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool before attempting to

service any of the hydraulic components.

ARO1760L

The hydraulic tank is pressurized. Lift the breather cap to

Figure 95

allow the pressurized air to vent. After the pressure has

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

service covers.

IMPORTANT

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

hydraulic tank, especially around the fill port and filter

ports.

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

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

used, guaranteed change interval is 1,000 hours.

NOTE: Based on the type of excavating being completed,

the working conditions (extremely hot or dusty) and

the extra front end attachments being used (hydraulic

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

changed more frequently.

Position the machine on firm, level ground. Swing upper

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

position bucket on ground as shown in Figure 96.

Set safety lever on "LOCK" position.

Shut down engine.

Release pressurized air from hydraulic tank by lifting

breather cap (1, Figure 99).

FG000356

Figure 96

Inspection, Maintenance and Adjustment

OP001005

4-53

Drain hydraulic oil from tank into a container capable of

holding 280 liters (74 U.S. gal.). After draining tank, install

drain plug.

IMPORTANT

Be careful of squirting oil when removing drain plug.

NOTE: Used filter and used oil should always be

disposed of according to local regulations.

FG014339

Figure 97

Carefully remove bolts and cover (2, Figure 99) from top of

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

will force the cover up.

Remove spring (3, Figure 99) and strainer (5), by pulling on

rod (4).

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

broken.

Position strainer (5, Figure 99) on boss portion of suction

pipe (6).

NOTE: Measurement "A" is 612.5 mm (24.11 in).

HAOC411L

Figure 98

10.

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

side of tank.

11.

Place spring (3, Figure 99) on rod (4) and assemble cover

(2).

12.

After replacing and cleaning the hydraulic oil, filter and

strainer, vent the system. See

“Venting and Priming

Hydraulic System” on page 4-83.

IMPORTANT

When the hydraulic breaker is being used, due to the

higher heat generated by this unit, use replacement

intervals recommended under the “Hydraulic Oil and

Filter Service Intervals” on page 3-36.

13.

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

ARO1720L

Figure 99

Inspection, Maintenance and Adjustment

OP001005

4-54

4,000 HOUR / BIENNIAL

SERVICE

Major Parts - Periodic Replacement

To ensure safe operation and work, perform periodic

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

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

and fatigue. Exchange these parts with new ones at the

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

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

Use only original equipment manufacturers parts.

Major Component

Parts Name to be Exchanged Periodically

Time to Exchange

Engine

Fuel hose (Tank to fuel prefilter)

Fuel hose (Fuel prefilter to fuel cooler)

Fuel hose (Fuel cooler to ECU)

Fuel hose (Tank to CP pump)

Heater hose (Heater to engine)

Heater hose (Heater to radiator)

Air Conditioner hose

Hydraulic

Body

Pump suction hose

2 years or 4,000 hours

System

Pump discharge hoses

Pump side branch hoses

Swing motor hoses

Travel motor hoses

Work

Boom cylinder line hoses

Device

Arm cylinder line hoses

Bucket cylinder line hoses

Inspection, Maintenance and Adjustment

OP001005

4-56

12,000 HOUR / 6 YEAR SERVICE

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)

European regulations state that the in-service life of any

hydraulic hose may not exceed six years. DOOSAN

recommends the following;

•

Hoses at the customer premises cannot be stored

more than 2 years before being discarded or installed

on a machine.

•

In-service lifetime of hoses fitted on a machine can

never exceed 6 years, but replace hoses described in

“Major Parts - Periodic Replacement” on page 4-56,

every

2 years. Always replace hoses having

exceeded the allowed in-service lifetime irrespective

of the external appearance/wear.

•

Always store hoses in a dark place at a maximum of

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

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

away from copper, manganese or tube generating

Ozone.

Inspection, Maintenance and Adjustment

OP001005

4-57

AIR-CONDITIONING SYSTEM

NOTE: See

“Clean Air-Conditioning Outer Filter” on

page 4-36.

Check Control Panel

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

displayed on the LCD display.

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

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

Check Air Conditioner Hoses

Check the hose for cracking and damage.

CAUTION

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

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

Check Condenser

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

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

Cooler and Air Conditioner Condenser Core” on

page 4-38.

Check Magnetic Clutch

Check the magnetic clutch for dirt and interference.

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

check the magnetic clutch.

Check Belt Tension

NOTE: See “Check Engine Fan Belt Tension” on page 4-29.

Inspection, Maintenance and Adjustment

OP001005

4-58

BOLT AND NUT INSPECTION

Inspect ALL fasteners after the first 50 hours of operation and

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

tighten them or install new hardware. Always use a calibrated

torque wrench.

IMPORTANT

Always clean fasteners before tightening.

If counterweight is loose, contact a DOOSAN distributor or

sales agent.

BOLT

TORQUE

NO.

POINT TO BE INSPECTED

DIA.

QTY.

HEAD

kg•m

ft lb

SIZE

Joint bolt with engine

pump side

11.2

110

mounting bracket and

fan side

11.2

110

engine

Joint bolt and nut

pump side

451

333

between engine mount-

fan side

265

195

ing bracket and frame

Radiator mounting bolt

539

398

Tightening bolt for hydraulic oil tank

265

195

Tightening bolt for fuel tank

265

195

Tightening bolt for pump

17 (S)

480

354

Tightening bolt for control valve

265

195

Tightening bolt for swing reduction device

931

687

Tightening bolt for swing motor

10 (S)

108

Tightening bolt for battery

Joint bolt with cabin mounting rubber and

6.5

frame

Joint bolt with cabin mounting rubber and

206

152

cabin

Joint bolt with swing bearing and upper

931

687

frame

Joint bolt with swing bearing and bottom

931

687

frame

Tightening bolt for travel device

480

354

Tightening bolt for sprocket

480

354

Tightening bolt for upper roller

539

398

Tightening bolt for bottom roller

539

398

Tightening bolt for track guard

539

398

Bolt for track shoes

384

115

1127

832

Fixing bolt for front pin

265

195

Breaker Filter (Optional)

265

195

Grease valve for track adjuster

PF 1/2

137

101

Inspection, Maintenance and Adjustment

OP001005

4-59

Joint bolt with engine mounting bracket and engine

1) Pump side

•

Tool: 19 mm (

)

•

Torque:11.2 kg•m (110 Nm, 81 ft lb)

FG015486

Figure 100

2) Fan side

•

Tool: 19 mm (

)

•

Torque: 11.2 kg•m (110 Nm, 81 ft lb)

FG015487

Figure 101

Joint bolt and nut between engine mounting bracket and

frame

1) Pump side

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG015488

Figure 102

2) Fan side

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG015489

Figure 103

Inspection, Maintenance and Adjustment

OP001005

4-60

Radiator mounting bolt

•

Tool: 30 mm (

)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG000446

Figure 104

Tightening bolt for hydraulic oil tank

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG000447

Figure 105

Tightening bolt for fuel tank

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG000448

Figure 106

Tightening bolt for pump

•

Tool: 17 mm (

)

•

Torque: 49 kg•m (480 Nm, 354 ft lb)

FG000449

Figure 107

Inspection, Maintenance and Adjustment

OP001005

4-61

Tightening bolt for control valve

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG000450

Figure 108

Tightening bolt for swing reduction device

•

Tool: 36 mm (

)

•

Torque: 95 kg•m (931 Nm, 687 ft lb)

FG000451

Figure 109

Tightening bolt for swing motor

•

Tool: 10 mm (

)

•

Torque: 11 kg•m (108 Nm, 80 ft lb)

FG000452

Figure 110

10. Tightening bolt for battery

•

Tool: 17 mm (

)

•

Torque: 5 kg•m (49 Nm, 36 ft lb)

FG000453

Figure 111

Inspection, Maintenance and Adjustment

OP001005

4-62

11. Joint bolt with cabin mounting rubber and frame

•

Tool: 17 mm (

)

•

Torque: 6.5 kg•m (64 Nm, 47 ft lb)

FG000454

Figure 112

Joint bolt with cabin mounting rubber and cabin

•

Tool: 24 mm (

)

•

Torque: 21 kg•m (206 Nm, 152 ft lb)

FG000455

Figure 113

12. Joint bolt with swing bearing and upper frame

•

Tool: 36 mm (

)

•

Torque: 95 kg•m (931 Nm, 687 ft lb)

FG000456

Figure 114

Joint bolt with swing bearing and bottom frame

•

Tool: 36 mm (

)

•

Torque: 95 kg•m (931 Nm, 687 ft lb)

FG000457

Figure 115

Inspection, Maintenance and Adjustment

OP001005

4-63

13. Tightening bolt for travel device

•

Tool: 30 mm (

)

•

Torque: 49 kg•m (480 Nm, 354 ft lb)

FG000458

Figure 116

Tightening bolt for sprocket

•

Tool: 30 mm (

)

•

Torque: 49 kg•m (480 Nm, 354 ft lb)

FG000459

Figure 117

14. Tightening bolt for upper roller

•

Tool: 30 mm (

)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG000460

Figure 118

15. Tightening bolt for bottom roller

•

Tool: 30 mm (

)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG000461

Figure 119

Inspection, Maintenance and Adjustment

OP001005

4-64

BUCKET

Bucket Tooth Replacement

WARNING

Due to the possibility of flying metal objects, always wear

safety helmet, protective gloves and eye protection when

changing bucket teeth.

Curl the bucket upwards and place the round rear surface

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

lock out the hydraulic controls before working on the

bucket.

NOTE: These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers

buckets, refer to their specific instructions.

HAOC680L

Figure 125

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

tooth wear or breakage has not developed. Do not allow

replaceable bucket teeth to wear down to a point that

bucket adapter is exposed. See Figure 125.

To replace a tooth (1, Figure 126), use a hammer and

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

tooth adapter (4).

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

scrape adapter as clean as possible.

Slide new tooth into position and insert lock washer.

FG000346

Figure 126

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

until lock washer seats in locking groove.

Inspection, Maintenance and Adjustment

OP001005

4-67

Bucket O-ring Replacement

WARNING

Due to possibility of flying metal objects, always wear

safety helmet, protective gloves and eye protection when

changing pins.

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

FG000502

damaged, replacement is necessary.

Figure 127

Roll old O-ring (1, Figure 128) onto boss (2) around bucket

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

(4) out of way.

ARO1390L

Figure 128

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

Figure 129) onto bucket boss (2). Make sure that O-ring

groove on both bucket link

(4) and boss have been

cleaned.

Realign arm or link with bucket pin hole and insert bucket

pin (3, Figure 128).

ARO1391L

Figure 129

Roll new O-ring (1, Figure 130) into O-ring groove.

ARO1392L

Figure 130

Inspection, Maintenance and Adjustment

OP001005

4-68

BUCKET SHIMMING

PROCEDURES

New Bucket Installation

If a new bucket is being installed on the excavator,

measure the inside dimension between the bucket ears

and the outside dimension across the arm mounting boss.

Subtract the clearance on both sides from the difference of

the two and shim accordingly, before assembly.

WARNING

To check end play (side to side) clearance at bucket

attachment point, the bucket must be free to move but

at all other times lower it to the ground or use support

blocks to immobilize this assembly. Shut off engine

and tag and lock out controls to prevent movement

during this procedure.

Inspection, Maintenance and Adjustment

OP001005

4-69

Shimming Procedures for Installed Bucket

FG000415

Figure 131

Reference

Description

Number

No Clearance

Plate

Arm

Bolt

Bucket Clearance

Hard Washer

Shim

Flange

Bucket Boss

With bucket attached, curl bucket and arm outward and

lower boom so that bucket teeth are pointing away from

excavator, just a few inches off ground. This position

provides easy accessibility for dimensional measurements.

Force bucket to one side and check for end play (side to

side) clearance under O-rings at attachment point. Total

clearance should be 1 mm (0.04 in) between side face of

boss and inside edge of ear bushing (3, Figure 131). Too

tight a fit (less than 1 mm (0.04 in)) can cause excessive

wear while too much clearance may produce excessive

noise and potentially hazardous slack control.

Recheck end play by forcing bucket towards opposite side

and repeating clearance measurements.

If an adjustment is required, detach stopper (6, Figure 131)

and bolts (7, Figure 131). Add or remove shims (4, Figure

131) as required. Use shims (4, Figure 131) on one side.

Tighten bolts with torque (27 kg•m) (7, Figure 131).

Inspection, Maintenance and Adjustment

OP001005

4-70

ELECTRICAL SYSTEM

NOTE: Never disassemble electrical or electronic parts.

Consult with a DOOSAN distributor or sales agency

before servicing.

Battery

WARNING

Battery electrolyte contains sulfuric acid and can quickly

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

yourself, immediately flush the area with water.

Battery acid could cause blindness if splashed into the

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

large quantities of water and see a doctor at once.

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

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

prevention center immediately.

When working with batteries, always wear safety glasses or

goggles.

Battery generates hydrogen gas, so there is danger of an

explosion. Do not bring lighted cigarettes near the battery,

or do anything that will cause sparks.

Before working with batteries, shut down engine and turn

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

Avoid short circuiting the battery terminals through

accidental contact with metallic objects, such as tool.

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

terminal and negative (-) terminal.

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

terminal. When installing the battery, first connect the

positive (+) terminal.

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

contact may generate sparks that will cause an explosion.

When installing the terminals, install them tightly.

Batteries in Cold Weather

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

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

engine. Battery performance decreases as the temperature gets

lower.

In extremely cold weather, remove the batteries at night and

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

higher power level.

Inspection, Maintenance and Adjustment

OP001005

4-71

Inspection of Battery Electrolyte Level

This machine has two maintenance free batteries. They never

require the addition to water.

When the charge indicator becomes transparency, it means low

electrolyte state because of the leakage or charging system

error. Determine the cause of problem and replace the batteries

immediately.

Check Charging State

FG000347

Check charging state through the charging indicator.

Figure 132

•

GREEN: Sufficiently charged.

•

BLACK: Insufficient charged.

•

TRANSPARENT: Replace battery.

Check the Battery Terminals

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

Clean the battery terminals and the battery cable connectors. A

solution of baking soda and water will neutralize acid on the

battery surface, terminals, and cable connectors. Petroleum jelly

or grease can be applied to the connectors to help prevent

corrosion.

Battery Replacement

When the charging indicator indicates transparency state,

HAOU790L

replace the battery. The batteries should always be replaced in

Figure 133

pairs.

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

the new battery.

Inspection, Maintenance and Adjustment

OP001005

4-72

Fuses

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

electrical circuits and their components from being

damaged. See Figure 134. The fuses used are standard

automotive type fuses.

The section on “Fuse Identification” on page 4-74, lists the

circuits and the fuse amperage required for each circuit. If

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

failures.

HAOC670L

Do not insert a higher amperage fuse into a lower

Figure 134

amperage slot. Serious damage to the electrical

components or fire can result.

CAUTION

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

(OFF) position.

Fuse Boxes

There are two fuse boxes (Figure 135) on the left side of the

heater box. The fuses prevent electrical devices from

overloading or shorting.

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

the function and amperage of each fuse.

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

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

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

FG000110

fuse separates, check the circuit and repair the circuit.

Figure 135

CAUTION

Always replace fuses with the same type and capacity fuse

that was removed. Otherwise, electrical damage could

result.

Inspection, Maintenance and Adjustment

OP001005

4-73

Fuse Identification

Fuse Box (1)

Fuse Box (2)

FG000542

Figure 136

Fuse Box One

Fuse Box Two

No.

Name

Capacity

Name

Capacity

Warning Light (Optional)

10A

Horn

10A

2-pump (Optional)

10A

Quick Clamp (Optional)

10A

Cigar Lighter

10A

Travel Alarm (Optional)

10A

12V Power

10A

Auxiliary Mode

10A

Wiper, Washer

10A

Check Connector

10A

Lower Wiper (Optional)

10A

Pilot Cutoff

10A

Stereo

10A

Memory Backup

10A

Starter Switch, Hour

10A

Room Light

10A

Meter

Spare

30A

Cabin Light (Optional)

30A

Air Conditioner, Heater

20A

Work Light

20A

Shear, Breaker (Optional)

15A

Fuel Heater

20A

Instrument Panel, Pressure

Seat Heater (Optional)

15A

Sensor

e-EPOS, Booster, Travel

15A

Headlight

15A

speed changer, Booster

ECU

15A

Fuel Pump (Optional), Wiper

15A

Inspection, Maintenance and Adjustment

OP001005

4-74

ENGINE COOLING SYSTEM

General

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

can have many benefits to keeping a machine in good operating

condition. A properly functioning cooling system will; improve

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

Always use distilled water in the radiator. Contaminants in tap

water neutralize the corrosion inhibitor components. If tap water

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

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

that has been treated with a water softener also contains salt

that will cause corrosion of components. Water from creeks and

stagnant pools usually contains dirt, minerals and/or organic

material that are deposited in the cooling system and impair

cooling efficiency. Distilled water is the best.

Engine overheating is often caused by bent or clogged radiator

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

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

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

the tubes.

WARNING

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

Always wear goggles when using compressed air.

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

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

could result in damage to engine cylinder heads.

Heavy duty diesel engines require a balanced mixture of water

and antifreeze. Drain and replace the mixture every year or

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

eliminate buildup of harmful chemicals.

Antifreeze is essential in any climate. It broadens the operating

temperature range by lowering the coolant's freezing point and

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

in the mixture unless additional freeze protection is required.

Never use more than 68% antifreeze under any condition.

Inspection, Maintenance and Adjustment

OP001005

4-75

Types of Antifreeze

There are two main classifications of antifreeze available on the

market today.

Ethylene Glycol - Doosan Genuine Antifreeze Solution

(for all seasons)

Propylene Glycol - Doosan Genuine Antifreeze Solution

(for all seasons)

Ethylene glycol has been on the market for many years. Its

chemical properties do not provide the improved corrosion

resistance that propylene glycol does. Ethylene glycol is also

very hazardous to the environment, people and animals.

DOOSAN recommends that ethylene glycol be replaced with

propylene glycol.

The newer propylene glycol antifreeze comes in many different

colors. Some of the colors are pink, red, orange and yellow.

There are even some that come in a blue-green color. The

blue-green color makes it very difficult to tell the difference of

what type of antifreeze is in a cooling system. The colors are

only a dye added to the clear antifreeze. Do not rely on color.

Keep careful machine records of what brand and type of

antifreeze is used in the unit. If you are unsure of what type of

antifreeze is in the system, drain and flush the system.

CAUTION

Do not mix the ethylene glycol and propylene glycol

solutions. If these two chemicals are mixed, undesirable

chemicals may be formed, which damages the equipment.

Do not mix up the solutions from different manufacturers.

Otherwise, the performance may be deteriorated. It is

recommended to use the Doosan Genuine Product.

In the regions under extreme weather, the user should

determine the performance of the coolant suitable for the

weather condition and decide the replacement cycle.

Inspection, Maintenance and Adjustment

OP001005

4-76

Antifreeze Concentration Tables

Ethylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons)

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-4°F)

67%

33%

-25°C (-13°F)

60%

40%

-30°C (-22°F)

56%

44%

-40°C (-40°F)

50%

Propylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons)

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

78%

22%

-15°C (5°F)

71%

29%

-20°C (-4°F)

65%

35%

-25°C (-13°F)

59%

41%

-30°C (-22°F)

55%

45%

-40°C (-40°F)

48%

52%

NOTE: Mixing ratio is for reference purpose only, and is not

an absolute standard.

NOTE: Replacement cycle of the Doosan Genuine Product is

2,000 hours or one year.

Inspection, Maintenance and Adjustment

OP001005

4-77

FUEL TRANSFER PUMP

(OPTIONAL)

WARNING

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

•

Cooling and lubrication of pump is achieved by

fuel passing through pump. If pump is dry

operated, heat generated by moving parts will

cause damage to pump rotors, vanes and seals.

To prevent unnecessary wear and/or damage to

pump do not dry operate fuel pump for more than

fifteen seconds.

Do not operate pump for more than fifteen minutes at a time.

•

Continuous usage of pump over recommended

time interval will cause overheating of motor and

will result in causing motor damage.

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

(Use only for diesel fuel.)

•

Do not use refueling pump for other types of fuel

which have a low flash point.

•

Do not use refueling pump for fuel contaminated

with water or high humidity. Moisture in pump

mechanism can cause rust and can create pump

failure.

Always operate pump using strainer installed on inlet hose.

This will prevent any foreign materials from being

introduced into pump. Always maintain pump and all of its

components in a clean condition.

•

If dirt or other foreign materials enter pump, it can

become lodged between the rotor and/or vanes

and generate heat which can cause pump

damage.

•

Do not remove strainer or use a strainer with

larger mesh to increase flow of fuel.

Be careful not to overfill or spill fuel.

Make sure direction of check valve is in line with flow

direction of fuel.

If any pump parts or components become lost, damaged or

inoperable, immediately replace it with a new ones.

IMPORTANT

If there are any sign of leakage while operating transfer

pump, inspect the following components to prevent any

fires or hazardous fuel spills.

•

Check all hoses leading to and from the transfer

pump.

•

Check all hose clamps.

•

Check transfer pump inlet port.

Inspection, Maintenance and Adjustment

OP001005

4-78

The transfer pump is used to transfer fuel from a refueling

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

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

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

from being introduced into transfer pump or fuel tank.

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

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

FUEL

FUEL TANK

OUT

FG000161

Figure 137

Reference

Description

Number

Body

Strainer Cap

Check Valve

Inlet Hose

Strainer

Remove strainer cap (4, Figure 137) from strainer (3) on

end of inlet hose (5).

NOTE: Keep strainer cap (4, Figure 137) in a safe

location to reseal strainer (3) after refueling is

complete.

Insert inlet hose (5, Figure 137) into refueling tank.

Turn fuel pump switch (Figure 138) inside of battery box on

front side to "I" (ON) position.

NOTE: Transfer pump rate of flow is approximately 35

liters/minute

(9.24 U.S. gpm). Use extra care

FG003379

not to overfill fuel tank so that fuel does not over

Figure 138

flow.

Once fuel transfer is completed, immediately turn switch to

"O" (OFF) position to stop pump.

Lift inlet hose (5, Figure 137) from fueling source and turn

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

remaining fuel from hose to fuel tank.

Install strainer cap (4, Figure 137) on inlet strainer (3) and

return hose (5) to storage position.

Inspection, Maintenance and Adjustment

OP001005

4-79

HANDLING OF ACCUMULATOR

WARNING

Even though the engine is stopped, the hydraulic

accumulators for the pilot system are still charged. Do not

disconnect any pilot system hoses until accumulator

pressure has been released from the circuit. To release

pressure, turn the starter switch to the "I" (ON) position and

operate all hydraulic control levers and forward/reverse

travel levers. Even though the engine is shutdown hydraulic

actuated components may move while releasing pilot

pressure. Keep all personnel away from excavator while

performing this operation.

•

Set safety lever on "LOCK" position after

stopping engine.

•

DO NOT mishandle accumulator(s). They are very

dangerous because they contain high-pressure

nitrogen gas.

•

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

accumulator.

•

DO NOT weld on accumulator, or try attaching

anything to it.

•

When replacing an accumulator, contact a

DOOSAN distributor or sales agency so the gas

can be properly released.

•

Wear safety goggles and protective gloves when

working on an accumulator. Hydraulic oil under

pressure can penetrate the skin and cause

serious injuries.

Release pilot accumulator pressure using the following

procedure;

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

attachment to the ground and shut down engine.

Set safety lever on "RELEASED" position.

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

Fully stroke work and travel levers in all directions.

Set safety lever on "LOCK" position.

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

switch.

Remove accumulator by unscrewing it slowly.

FG013208

Figure 139

Inspection, Maintenance and Adjustment

OP001005

4-80

TRACK TENSION

WARNING

Safely measuring track tension requires two people. One

person must be in the operator's seat, running the controls

to keep one side frame in the air, while the other person

makes dimensional checks. Take all necessary precautions

to make sure the machine won't move or shift position

during service. Warm up the engine to prevent stalls, travel

the excavator to an area that provides level, uniform ground

support and/or use support blocks when necessary.

The track adjusting mechanism is under very

high-pressure. NEVER release pressure too suddenly. The

grease cylinder valve should never be backed off more than

one complete turn from the fully snugged down position.

Bleed off pressure slowly and keep your body away from

the valve at all times.

Track shoe link pins and bushings wear with normal usage,

reducing track tension. Periodic adjustment is necessary to

compensate for wear and it may also be required by working

conditions.

Track tension is checked by jacking up one side of the

excavator. See Figure 140. Place blocking under frame

while taking measurement.

90 ~ 110

FG000345

Figure 140

Measuring the distance

(A, Figure

141) between the

bottom of the side frame and the top of the lowest crawler

shoe. Recommended tension for operation over most

types of terrain is 320 - 340 mm (12.60 - 13.39 in)

NOTE: This measurement can be thrown off if there is

too much mud or dirt or other material in the

track assembly. Clean off the tracks before

checking clearance.

Too little sag in the crawler track

(less than

320 mm

(12.60 in) clearance) can cause excessive component

FG000162

wear. The recommended adjustment can also be too tight

Figure 141

causing accelerated stress and wear if ground conditions

are wet, marshy or muddy, or if the ground is hard and full

of rocks or gravel.

Inspection, Maintenance and Adjustment

OP001005

4-81

The increased clearance recommended for muddy ground

conditions is between 340 - 370 mm (13.39 - 14.57 in). The

clearance should be approximately 370 mm (14.57 in) for

operation over gravel, rocky terrain, or over sand or snow.

WARNING

The track adjusting mechanism is under very

high-pressure. NEVER release pressure too suddenly.

The grease cylinder valve should never be backed off

more than 1 complete turn from the fully snugged

down position. Bleed off pressure slowly and keep

your body away from the valve at all times. If there is

problem in the fitting thread, the valve or fitting might

be ejected at high speed to cause fatal wound.

Track tension adjustments are made through the grease

fitting

(1, Figure 142) in the middle of each side frame.

Adding grease increases the length of an adjustment

cylinder

(2). The longer the adjustment cylinder, the

greater the pressure on the tension spring pushing the

track idler wheel outward.

If there is not enough slack or clearance in the tracks and

the adjustment is too tight, the idler wheel and adjusting

cylinder can be retracted by bleeding off grease through

hole in valve (3, Figure 142) by loosening valve slowly (3,

Figure 142).

FG000163

Figure 142

NOTE: After track tension is adjusted by loosening

valve, be sure to tighten valve (3, Figure 142)

with 14 kg•m (137 Nm, 101 ft lb).

WARNING

Do not loosen or remove the grease fitting (1, Figure

142) until the pressure is entirely bleed off by

loosening valve (3, Figure 142) slowly.

Inspection, Maintenance and Adjustment

OP001005

4-82

VENTING AND PRIMING

HYDRAULIC SYSTEM

Main System Pump

NOTE: If pump is run without sufficient oil in the main

hydraulic pump, damage can occur. Always vent

pump of air after draining hydraulic system.

With the engine stopped, remove vent plug (Figure 143) to

see if any oil is present.

If oil is not present, fill pump with oil through port (Figure

143).

Install vent plug (Figure 143) first.

FG000158

Figure 143

Start engine and run it for several minutes at low idle

engine speed. This will pressurize the hydraulic oil tank

and system.

Slowly loosen vent plug (Figure 143) several turns, until

hydraulic oil flows out of plug. This shows that air has been

released.

Tighten the plug (Figure 143).

Hydraulic Cylinders

IMPORTANT

If cylinders are operated in high idle after the hydraulic

system has been drained or the cylinder has been rebuilt,

damage to piston packing and seals may occur. Always

vent air from cylinders at low idle and at a slow speed.

Run engine at low idle. Extend and retract each cylinder to

within 100 mm (4 in) of fully stroking it 4 - 5 times.

Operate fully extend and retract each cylinder 3- 4 times.

Repeat procedure until cylinders extend and retract

smoothly.

Inspection, Maintenance and Adjustment

OP001005

4-83

Swing Motor

IMPORTANT

If the air is not vented from the system, it will cause damage

to the swing motor and bearings.

NOTE: Perform this only when oil has been drained from

swing motor.

FG000159

Shut down engine.

Figure 144

Disconnect drain hose and fill swing motor case with

hydraulic oil.

Connect the drain hose.

Start engine and set throttle at "LOW IDLE" and swing

upper structure slowly two full revolutions to the left and

right.

Travel Motor

NOTE: Perform this only when oil is drained from travel

motor

Shut down engine

Disconnect drain hose (Figure 145) and fill motor case with

hydraulic oil.

Connect drain hose.

Start engine and set engine speed control dial to "LOW

FG000160

IDLE." Run the engine for one minute and slowly drive

Figure 145

excavator forwards and backwards.

General Venting

After venting air from all components, shut the engine

down and check the hydraulic oil level. Fill hydraulic oil

tank to "H" mark on sight gauge.

Start engine and operate all controls again, run engine for

five minutes to ensure all systems have been vent and

purged of air. Set engine speed to "LOW IDLE," and check

hydraulic oil level again. Add oil as necessary.

Check for oil leaks and clean all fill and venting locations.

Inspection, Maintenance and Adjustment

OP001005

4-84

LONG TERM STORAGE

When a machine is taken out of service and stored for a time

exceeding 30 days, steps must be taken to protect the machine.

Leaving equipment outdoors exposed to the elements will

shorten its life.

An enclosure will protect the machine from rapid temperature

changes and lessen the amount of condensation that forms in

hydraulic components, engine, fuel tank, etc. If it is not possible

to put the machine in an enclosure, cover it with a tarpaulin.

FG014341

Check that the storage site is not subject to flooding or other

Figure 146

natural disasters.

After the machine has been positioned for storage and the

engine shut down, perform the following operations:

Before Storage

Keep the excavator in the position shown in Figure 92 to prevent

rust of the hydraulic piston rods.

•

Inspect for damaged, loose or missing parts.

•

Repaint necessary area to prevent oxidation.

•

Wash and clean all parts of machine.

•

Store the machine indoor, stable place. If stored

outside, cover with a waterproof tarpaulin.

•

Perform lubrication procedures on all grease points.

•

Apply a coating of light oil to the exposed plated

metal surfaces (such as hydraulic cylinder rods, etc.)

and to all the control linkage and control cylinders.

(Control valve spools, etc.)

•

Remove the battery from the excavator to be fully

charged and stored.

•

Inspect the coolant recovery tank and radiator to

make sure the antifreeze level in the system is

correct. Make sure that antifreeze concentration is

enough for the lowest temperature anticipated during

storage.

•

Seal all external openings (i.e. engine exhaust outlet,

crankcase and hydraulic breather, fuel vent line, etc.)

with tape wide enough to cover the opening,

regardless of size.

NOTE: When sealing with tape, be sure to extend

tape approximately one inch

(25 mm)

beyond opening to insure a good seal.

Inspection, Maintenance and Adjustment

OP001005

4-85

During Storage

•

Once a month, start the engine and follow the

"Hydraulic Oil Warm-up" procedures listed in this

manual.

NOTE: Remove all seals from the machine (i.e.

crankcase and hydraulic breathers, engine

air intake, fuel tank vent lines, etc.).

Operate hydraulic functions for traveling, swing and

digging two or three times for lubrication after

"Hydraulic Oil Warm-up." Coat all the moving parts

and surfaces of the components with a new oil film

after operating. At the same time, charge the battery.

Rotate track to prevent track seizing. "

•

Every 90 days, use a hydrometer to measure the

protection of the coolant. Refer to the antifreeze/

coolant protection chart to determine protection of the

cooling system. Add coolant as required.

After Storage

•

When operating the work equipment, remove all

grease from the hydraulic cylinder rods.

•

Add grease and oil at all lubrication points.

•

Adjust fan and alternator belt tension.

•

Connect the charged battery.

•

Check condition of all hoses and connections.

•

Check the levels of engine oil, fuel, coolant and

hydraulic circuit oil. If there is water in the oil, change

all the oil.

•

Change all filter elements.

•

When starting the engine after long-term storage,

follow the "Hydraulic Oil Warm-up" procedures listed

in this manual.

Inspection, Maintenance and Adjustment

OP001005

4-86

MAINTENANCE IN SPECIAL

CONDITIONS

NOTE: See

“Operation Under Unusual Conditions” on

page 3-42 for other recommendations.

Conditions

Maintenance Required

Operating in mud, water or rain.

Perform a walk around inspection to check for any loose

fittings, obvious damage to the machine or any fluid leakage.

After completing operations, clean mud, rocks or debris from

the machine. Inspect for damage, cracked welds or loosened

parts.

Perform all daily lubrication and service.

If the operations were in salt water or other corrosive materials,

make sure to flush the affected equipment with fresh water.

Operating in an extremely dusty or hot

Clean the air intake filters on a more frequent basis.

environment.

Clean the radiator and oil cooler fins to remove embedded dirt

and dust.

Clean the fuel system intake strainer and fuel filter more

frequently.

Inspect and clean as required the starter and alternator.

Operating in rocky terrain.

Check the undercarriage and track assemblies for damage or

excessive wear.

Inspect for loose or damaged fittings or bolts.

Relax track tension.

On a more frequent basis, inspect the front end attachments for

damage or excessive wear.

Install a top guard and front guard as required for protection

against falling rock.

Operating in extreme cold.

Use the proper fuel for the temperature conditions.

Using a hydrometer, check the antifreeze to make sure that it is

providing the proper cold weather freeze protection.

Verify the condition of the batteries. In extremely cold weather

remove the batteries at night and store them in a warmer area.

Remove mud buildup as soon as possible to prevent it from

freezing to the undercarriage and causing damage.

Inspection, Maintenance and Adjustment

OP001005

4-87

OP001006

5Transportation

Obey all local, state or federal regulations for the transportation

of the excavator. If unsure of regulations check with local

authorities.

Check the intended route for road width, overhead clearances,

weight restrictions, and traffic control regulations. Special

approval or permits may be required.

LOADING AND UNLOADING

Warning for Counterweight and Front

Attachment Removal

DANGER

DOOSAN warns any user, that the removal of the

counterweight from the machine, front attachment or any

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

could cause unexpected movement, resulting in death or

serious injuries. DOOSAN is not liable for any misuse.

Never remove the counterweight or front attachment unless

the upper structure is in-line with the lower structure.

FG000371

Never rotate the upper structure once the counterweight or

Figure 1

front attachment has been removed.

Transportation

OP001006

5-1

WARNING

When transporting the machine, know the width, height,

length and weight.

Loading or unloading the machine can be a dangerous

operation. Make sure to run the engine at the lowest speed

setting, and travel at the slowest speed possible.

Make sure that the ramp being used can handle the weight

of the machine. If required, add blocking under the ramp for

additional support.

Make sure that the ramp surface is free of grease or mud

that could cause the machine to slip or slide.

Make sure that the trailer is parked on firm, level ground

before attempting to load/unload the excavator.

If it is required to turn the machine while it is on the trailer,

make sure to do this at the slowest engine and travel

speeds possible.

Make sure to secure the excavator onto the trailer as

required by local transportation laws.

Total Height

Total Width

Total Length

Weight

Remarks

6.25 m Boom

3,345 mm

3,200 mm

10,620 mm

29.3 metric tons

3.1 m Arm

(11' 0")

(10' 6")

(418.11 in)

(32.23 tons)

600 G Shoe

Make sure that the trailer is parked on firm, level ground.

See Figure 2.

Make sure that the ramps that are being used are designed

to handle the weight of the excavator. If required, add

90 ~ 110

blocking under the ramp to provide additional support.

The ramp angle should be less than or not exceeding a 15°

angle. Ramps steeper than this may cause a problem

when loading or unloading.

FG000325

Figure 2

Transportation

OP001006

5-2

Set the travel speed selector switch to "O" (OFF) position.

See Figure 3.

FG000023

Figure 3

Turn "OFF" auto idle selector button (1, Figure 4). The

indicator light will be disappeared.

Set engine speed to "LOW IDLE."

POWER

FG015474

Figure 4

If the machine is equipped with work equipment, set the

work equipment at the front, and travel forward to load it.

90 ~ 110

FG000325

Figure 5

The unit does not require disassembly for normal

over-the-road transportation. If the boom and arm need to

be removed, the counterweight will place more weight on

the rear of the machine. Make sure to back the excavator

onto the trailer so that the counterweight end of the

excavator is positioned on the ramp first. See Figure 6.

FG000326

Figure 6

Transportation

OP001006

5-3

Extend bucket and arm cylinders to maximum length and

then lower the boom slowly.

FG000327

Figure 7

10. Set safety lever on "LOCK" position.

Unlock

lock

FG001091

Figure 8

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

(Figure 9).

12. Remove key from starter switch.

FG000175

Figure 9

13. Make sure to secure the excavator onto the trailer before

transporting. Place blocking (1, Figure 10) in front of and

behind each track. Tie front and rear (2, Figure 12) and tie

down point (3, Figure 12) on the lower frame with wire

cable as required by local transportation laws.

14. Refer to the Dimensions for Transportation table and

drawing for overall machine height and width

measurements. Make sure to position the excavator as

shown. If not transported in this position, the height

measurements may be different.

FG000334

Figure 10

Transportation

OP001006

5-4

FG014870

Figure 11

LIFTING WITH SLING

WARNING

Improper lifting can allow load to shift and cause injury or

damage.

Refer to “Specification” on page 7-1 of this manual for

information on weight and dimensions.

Use properly rated cables and slings for lifting.

Position machine for a level lift.

Lifting cables should have a long enough length to prevent

contact with the machine. Spreader bars may be required.

NOTE: If spreader bars are used, be sure that cables

are properly secured to them and that the angle

Figure 12

of the cables is factored into the lift strength.

Transportation

OP001006

5-5

OP001007

6Troubleshooting

Anytime that a malfunction occurs, take immediate corrective

action. Check for and investigate the cause of the malfunction. A

schedule maintenance program can prevent malfunctions from

occurring by doing preventative maintenance. A systematic

approach should be taken to troubleshooting, since several

overlapping malfunctions may give the appearance of a problem

that does not exist. If cause for the malfunction cannot be

determined, contact your DOOSAN distributor. Never perform

an adjustment of or disassembly of, hydraulic components,

electrical and electronic components, without first consulting a

DOOSAN distributor.

ELECTRICAL SYSTEM

Problem

Cause

Remedy

Battery will not hold a

Low battery power.

Clean and retighten.

charge.

Alternator belt loose or bad.

Tighten or replace belt.

Loose or corroded terminals.

Tighten or replace as required.

Alternator faulty.

Repair or replace as required.

Low battery power.

Internal battery short.

Replace battery.

Short circuit in wiring.

Repair as required.

Engine speed is not

Speed control dial failed.

Replace control dial.

controllable.

Throttle controller failed.

Replace controller.

Speed control motor failed.

Repair or replace as required.

Blown fuse.

Replace fuse.

Wiring harness damaged.

Repair or replace as required.

Connector failed.

Repair or replace as required.

Work mode (Power mode or

Blown fuse.

Replace fuse.

Economy mode) selector

Work mode selector switch failed.

Replace switch.

does not work.

Connector failed.

Replace connector.

Wiring harness damaged.

Repair or replace as required.

e-EPOS controller failed.

Repair or replace as required.

Troubleshooting

OP001007

6-1

Problem

Cause

Remedy

Working mode selector does

Blown fuse.

Replace fuse.

not work.

Working mode selector switch.

Replace switch failed.

Connector failed.

Replace connector.

Wiring harness damaged.

Repair or replace as required.

e-EPOS controller failed.

Repair or replace as required.

ENGINE

Problem

Cause

Remedy

Starter does not operate.

Low battery power.

Charge battery.

Poor terminal contact.

Clean and tighten connections.

Starter switch failed.

Replace switch.

Starter relay failed.

Replace relay.

Starter controller failed.

Replace controller.

Wiring harness faulty.

Replace harness.

Battery relay failed.

Replace relay.

Blown fuse.

Replace fuse.

Starter engages, engine

Fuel gelled in cold weather.

Replace fuel.

does not start.

Fuel filters plugged.

Replace filters.

Water or dirt in fuel system.

Clean system and add new fuel.

Air in fuel system.

Purge air from system.

Engine stop control failed.

Contact your DOOSAN dealer.

Engine stop relay failed.

Replace relay.

Blown fuse.

Replace fuse.

Engine starts, runs only at

Engine oil viscosity incorrect.

Change oil.

low speed or shuts down.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine stop motor cable out

Readjust

adjustment.

Engine speed control cable out of

Readjust

adjustment.

Troubleshooting

OP001007

6-2

Problem

Cause

Remedy

Engine knocks, runs

Low engine oil.

Refill.

unevenly or surges.

Plugged air intake system.

Clean system and replace filter.

Injection pump out of adjustment.

Contact your DOOSAN dealer.

Plugged fuel filter.

Replace fuel filter.

Water or dirt in fuel system.

Clean system and add new fuel.

Clogged or dirty fuel injectors.

Clean injectors.

Engine has poor power.

Plugged air intake system.

Clean system and replace filter.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine speed control cable out of

Readjust.

adjustment.

Injection pump out of adjustment.

Contact your DOOSAN dealer.

Valve backlash faulty.

Adjust backlash.

Engine runs hot.

Low coolant level.

Add coolant.

Thermostat faulty.

Replace thermostat.

Radiator cap faulty.

Replace radiator cap.

Radiator core plugged.

Clean radiator.

Oil cooler core plugged.

Clean oil cooler.

Fan belt loose or damaged.

Tighten or replace as required.

Temperature sensor faulty.

Replace sensor.

HYDRAULIC SYSTEM

Problem

Cause

Remedy

None of the controls

Hydraulic pump failed.

Contact your DOOSAN dealer.

function (loud noise from

Low hydraulic oil level.

Add hydraulic oil as required.

pumps).

Suction line plugged or damaged.

Clean or replace as required.

None of the controls

Pilot pump failure.

Contact your DOOSAN dealer.

function (no noise from

Cut off solenoid valve failed.

Replace solenoid.

pumps).

Pilot cutoff switch is ON.

Adjust pilot cutoff switch clearance.

Troubleshooting

OP001007

6-3

Problem

Cause

Remedy

All actuators have low

Low hydraulic oil level.

Add hydraulic oil as required.

power.

Suction filter clogged.

Clean filter.

Hydraulic pumps faulty.

Contact your DOOSAN dealer.

Main relief pressure too low.

Contact your DOOSAN dealer.

Hydraulic pumps excavating.

Bleed air from hydraulic pumps.

Only one or two actions

Overload relief pressure too low.

Reset pressure.

have little or no power.

Makeup check valve leaking.

Clean or replace as required.

Control valve spool faulty.

Replace valve spool.

Dirt in valve spool.

Clean or replace as required.

Actuator failed.

Repair or replace as required.

Cylinder seal failed.

Repair or replace as required.

Cylinder rod damaged.

Repair or replace as required.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

Oil temperature too high.

Oil cooler faulty.

Contact your DOOSAN dealer.

Fan belt loose.

Tighten fan belting as required.

SWING SYSTEM

Problem

Cause

Remedy

No swinging motion.

Swing brake valve faulty.

Replace brake valve.

Hydraulic timer faulty.

Replace timer.

Low brake release pressure.

Adjust pressures.

Swing motor failed.

Replace swing motor.

Remote control valve failed.

Replace control valve.

Wrong pilot line connection.

Reconnect pilot lines.

Swing motion jerky.

Swing gear worn.

Replace swing gear.

Swing bearing damaged.

Replace bearing.

Improper lubrication.

Add grease.

Troubleshooting

OP001007

6-4

TRAVEL SYSTEM

Problem

Cause

Remedy

Travel motion does not

Center joint leaking.

Repair or replace as required.

function.

Parking brake will not release.

Repair parking brake.

Travel motor failed.

Repair or replace as required.

Remote control valve failed.

Repair or replace as required.

Wrong pilot line connection.

Reconnect pilot lines.

Travel speed is too low.

Track tension too high or too low.

Adjust tension.

Damaged rollers or idlers.

Repair or replace as required.

Track frame damaged.

Repair as required.

Parking brake will not release.

Repair parking brake.

Troubleshooting

OP001007

6-5

OP001008

7Specification

STANDARD SPECIFICATION

SPECIFICATION

COMPONENT

METRIC

ENGLISH

Bucket

CECE

1.1 m³

1.44 yd³

capacity

PCSA

1.27 m³

1.66 yd³

Equipment weight

29.6 metric tons

32.6 tons

Engine

Model

DE08TIS

Type

Water cooled - 6 cylinders

Rated output

200 ps @1,900 rpm

197 hp @1,900 rpm

Maximum torque

86 kg•m @ 1,300 rpm

622 ft lb @ 1,300 rpm

Fuel tank capacity

500 liters

132 U.S. gal.

Hydraulic

Type

Axial piston

pump

Discharging pressure

350 kg/cm²

5,000 psi

Maximum discharge quantity

2 x 247 liters/min

2 x 65.2 U.S. gpm

Hydraulic oil

Tank Level

160 liters

42 U.S. gal.

capacity

System

280 liters

74 U.S. gal.

Performance

Digging

Bucket

18.0 metric tons

19.8 tons

capability

Arm

13.4 metric tons

14.8 tons

Swing speed

9.9 rpm

Travel speed

High speed

5.1 km/h

3.17 MPH

Low speed

3.0 km/h

1.86 MPH

Traction force

High speed

13.7 metric tons

15.1 tons

Low speed

25.2 metric tons

27.7 tons

Gradeability

35° (70% slope)

Ground pressure

0.56 kg/cm²

7.97 psi

Ground clearance

500 mm

19.7 in

Track shoe width

600 mm

23.6 in

Upper roller qty.

2 per side

Bottom roller qty.

9 per side

Specification

OP001008

7-1

OVERALL DIMENSIONS

FG000316

Figure 1

6.245 m (20' 6") BOOM

10.0 m (32' 10") BOOM

DIMENSION

3.1 m (10' 2") ARM

2.5 m (8' 2") ARM

3.75 m (12' 4") ARM

7.0 m (22' 12") ARM

10,620 mm (34' 10")

10,740 mm (35' 3")

10,660 mm (35' 0")

14,370 mm (47' 1")

3,200 mm (10' 6")

7,420 mm (24' 4")

7,540 mm (24' 9")

7,460 mm (24' 6")

11,165 mm (36' 7")

4,040 mm (13' 2")

4,940 mm (16' 2")

1,150 mm (3' 10")

3,345 mm (10' 12")

3,475 mm (11' 5")

3,455 mm (10' 12")

2,960 mm (9' 9")

1,500 mm (4' 11")

1,460 mm (4' 9")

2,600 mm (8' 6")

3,200 mm (10' 6")

600 mm (23.62 in)

500 mm (19.69 in)

3,065 mm (10' 1")

Specification

OP001008

7-2

WORKING RANGE

G.L

-1

-2

-3

-4

-5

-6

-7

-8

Figure 2

FG000318

BOOM

6.245 m (20' 6")

10.0 m (32' 10")

DIM.

ARM

3.1 m (10' 2")

2.5 m (8' 2")

3.75 m (12' 4")

7.0 m (22' 12")

Max. Digging

10,745 mm (35' 3")

10,170 mm (33' 4")

11,270 mm (36' 12")

17,520 mm (57' 6")

Reach

Max. Digging

7,360 mm (24' 2")

6,760 mm (22' 2")

8,010 mm (26' 3")

13,855 mm (45' 5")

Depth

Max. Digging

10,330 mm (33' 11")

9,970 mm (32' 8")

10,410 mm (34' 2")

14,175 mm (46' 6")

Height

Max. Loading

7,260 mm (23' 10")

6,930 mm (22' 9")

7,365 mm (24' 2")

11,950 mm (39' 2")

Height

Min. Swing

4,050 mm (13' 3")

4,095 mm (13' 5")

4,065 mm (13' 4")

6,125 mm (20' 1")

Radius

Specification

OP001008

7-3

APPROXIMATE WEIGHT OF

WORKLOAD MATERIALS

IMPORTANT

Weights are approximations of estimated average volume

and mass. Exposure to rain, snow or ground water; settling

or compaction due to overhead weight and chemical or

industrial processing or

changes due to thermal or

chemical transformations

could

all

increase value of

weights listed in table.

LOW WEIGHT OR

MEDIUM WEIGHT OR

HIGH WEIGHT OR

DENSITY

MATERIAL

1,100 KG/M³

1,600 KG/M³

2,000 KG/M³

(1,850 LB/YD³), OR

(2,700 LB/YD³), OR

(3,370 LB/YD³), OR

LESS

401 kg/m

Charcoal

---------------------

(695 lb/yd³)

433 kg/m

Coke, blast furnace size

---------------------

(729 lb/yd³)

449 kg/m

Coke, foundry size

---------------------

(756 lb/yd³)

801 kg/m

Coal, bituminous slack, piled

---------------------

(1,350 lb/yd³)

881 kg/m

Coal, bituminous r. of m., piled

---------------------

(1,485 lb/yd³)

897 kg/m

Coal, anthracite

---------------------

(1,512 lb/yd³)

1,009 kg/m

Clay, DRY, in broken lumps

---------------------

(1,701 lb/yd³)

1,746 kg/m

Clay, DAMP, natural bed

---------------------

(2,943 lb/yd³)

1,506 kg/m

Cement, Portland, DRY granular

---------------------

(2,583 lb/yd³)

1,362 kg/m

Cement, Portland, DRY clinkers

---------------------

(2,295 lb/yd³)

1,522 kg/m

Dolomite, crushed

---------------------

(2,565 lb/yd³)

1,202 kg/m

Earth, loamy, DRY, loose

---------------------

(2,025 lb/yd³)

1,522 kg/m

Earth, DRY, packed

---------------------

(2,565 lb/yd³)

1,762 kg/m

Earth, WET, muddy

---------------------

(2,970 lb/yd³)

Specification

OP001008

7-4

LOW WEIGHT OR

MEDIUM WEIGHT OR

HIGH WEIGHT OR

DENSITY

MATERIAL

1,100 KG/M³

1,600 KG/M³

2,000 KG/M³

(1,850 LB/YD³), OR

(2,700 LB/YD³), OR

(3,370 LB/YD³), OR

LESS

961 kg/m

Gypsum, calcined, (heated, powder)

---------------------

(1,620 lb/yd³)

1,522 kg/m

Gypsum, crushed to 3 inch size

---------------------

(2,565 lb/yd³)

1,810 kg/m

Gravel, DRY, packed fragments

---------------------

(3,051 lb/yd³)

1,922 kg/m

Gravel, WET, packed fragments

---------------------

(3,240 lb/yd³)

1,282 kg/m

Limestone, graded above 2

---------------------

(2,160 lb/yd³)

Limestone, graded

1,362 kg/m³

---------------------

1-1/2 or 2

(2,295 lb/yd³)

1,522 kg/m

Limestone, crushed

---------------------

(2,565 lb/yd³)

1,602 kg/m

Limestone, fine

---------------------

(2,705 lb/yd³)

1,282 kg/m

Phosphate, rock

---------------------

(2,160 lb/yd³)

929 kg/m

Salt

---------------------

(1,566 lb/yd³)

529 kg/m

Snow, light density

---------------------

(891 lb/yd³)

1,522 kg/m

Sand, DRY, loose

---------------------

(2,565 lb/yd³)

1,922 kg/m

Sand, WET, packed

---------------------

(3,240 lb/yd³)

1,362 kg/m

Shale, broken

---------------------

(2,295 lb/yd³)

529 kg/m

Sulphur, broken

---------------------

(1,620 lb/yd³)

Specification

OP001008

7-5

1INDEX

Numerics

Teeth and Side Cutters 4-21

1,000 Hour / 6 Month Service 4-43

Tooth 4-67

10 Hour / Daily Service 4-14

12,000 Hour / 6 Year Service 4-57

2,000 Hour / Yearly Service 4-49

Cabin Light 2-55

250 Hour / Monthly Service 4-27

Cabin Storage Compartments 2-65

4,000 Hour / Biennial Service 4-56

Cabin Work Light Switch 2-12

50 Hour / Weekly Service 4-24

Ceiling Cover 2-61

500 Hour / 3 Month Service 4-35

Charge Warning Light 2-24

Check and Confirmation After Stopping Engine

3-12

Abnormal State Warning Symbols 2-29

Cigarette Lighter 2-15

Adjust Valve Clearance 4-55

Circuit Breaker 2-55

Air Intake System 4-22

Clock 2-23, 2-38

Outer Element of Air Cleaner 4-39

Cold Weather Hydraulic System Warm-up 3-10

Replace Outer Air Cleaner Element 4-50

Cold Weather Starting 3-6

Alternator and Starter 4-55

Communication

Antifreeze Concentration Tables 4-77

Error Warning 2-28

Antivibration Shock Mounts 4-55

Indicator 2-27

Arm and Bucket Joint Pins 4-24

Component Locations 2-2

Ashtray 2-65

Constant Speed Button 2-14

Audio Control Panel 2-10

Coolant Temperature Warning Light 2-25

Auto Idle Mode 3-20

Cooling System

Auto Idle Selection 2-47

Clean Radiator, Oil Cooler and Air Conditioner

Auto Idle Selector Button 2-34

Condenser Coil 4-38

Auxiliary Mode Switch 2-9

Engine 4-75

Engine Coolant Temperature Warning Light

2-25

Oil Cooler Dust Net 4-20

Batteries 4-34

Radiator Coolant 4-51

Battery 4-71

Refill Cooling System 4-20

Box Door 2-68

Cracks and Faulty Welds 4-22

Electrolyte Level 4-72

Cup Holder 2-67

Terminals 4-72

Cycle Time Tests 4-55

Voltage 2-28

Bolt and Nut Inspection 4-59

Boom and Arm Joint Pins 4-27

Boost Mode 3-21

Description of Lubrication and Service Chart 4-10

Booster Button 2-17

Digital Clock 2-23

Booster Cable 3-7

Display Selection 2-37

Bucket 4-67

Display Selector Button 2-36

Installation 4-69

Door Side Latch 2-64

O-ring 4-68

Door Window Holder 2-67

Shimming Procedures 4-69

Down Arrow Button 2-36

Shimming Procedures for Installed Bucket 4-70

Index

950106-00077E

8-1

Engine Coolant Temperature Gauge 2-22

Economy Mode Selection 2-46

Fuel Gauge 2-22

Economy Mode Selector Button 2-33

Hour Meter 2-24

Electrical System 4-71, 6-1

Hydraulic Oil Temperature 2-23

Engine 6-2

Multifunction Gauge 2-23, 2-27

Adjust Valve Clearance 4-55

General Venting 4-84

Check and Adjust Engine 4-48

Check Warning Light 2-25

Coolant Temperature Gauge 2-22

Handling a New Excavator 3-1

Coolant Temperature Warning Light 2-25

Handling of Accumulator 4-80

Cover 2-68

Hanger 2-66, 2-67

Emergency Stop Switch 2-9

Head Bolt Torques 4-55

Fan Belt 4-29, 4-30

Headlight Switch 2-11

Head Bolt Torques 4-55

Heater and Air Conditioner 2-48

Oil and Filter 4-26, 4-33

Additional Operating Instruction 2-53

Oil Level 4-14

Control Panel 2-13, 2-49

Oil Pressure Warning Light 2-24

Filter 4-36, 4-47

Shutdown 3-11

Location of Controls and Vents 2-48

Speed 2-28

Memory Function of Used Mode 2-53

Speed Control Dial 2-8

Refrigerant 4-48

Start 3-4

System 4-58

Start and Stop 3-2

Horn Button 2-17

ESC Button 2-37

Hose Clamps 4-34

Excavator Rated Lift Capacity Tables 1-46

Hour Meter 2-24

Hydraulic System 6-3

Flow Control 2-44

Fan Belt 4-26

Front Hydraulic Pump Pressure 2-29

Filter / Oil Info 2-39

General Venting 4-84

Filter State 2-29

Hydraulic Breaker 3-32

Flow Control 2-44

Hydraulic Hoses and Tubing 3-32

Flow Control Button 2-34

Oil and Filter 3-36

Front

Operation 3-33

Bottom Window 2-63

Selection 3-32

End Attachments 4-34

Hydraulic Cylinders 4-83

Hydraulic Pump Pressure 2-29

Hydraulic Oil Exchange 4-53

Upper Windows 2-62

Hydraulic Oil Return Filter 4-34, 4-44

Windows 2-62

Hydraulic Oil Tank 4-15

Fuel

Hydraulic Oil Temperature Gauge 2-23

Filter 4-42

Leaks in the Hydraulic System 4-16

Gauge 2-22

Main System Pump 4-83

Heater Switch 2-16

Oil Exchange 4-53

Level 4-17

Rear Hydraulic Pump Pressure 2-29

System 4-42

Swing Motor 4-84

Transfer Pump 4-78

Warm-up 3-9

Tank Drain Valve 4-26

Transfer Pump 4-78

Fuse

Indicator

Boxes 2-56, 4-73

Communication Indicator 2-27

Fuses 4-73

Indicator Lights

Fusible Link 2-56

Charge Warning Light 2-24

Identification 4-74

Coolant Temperature Warning Light 2-25

Engine Check Warning 2-25

Engine Oil Pressure Warning Light 2-24

Gauges

Preheating Indicator Light 2-26

Index

950106-00077E

8-2

Work Light 2-26

High Altitudes 3-45

Inspecting Engine Before Starting 3-2

Rainy or Humid Conditions 3-44

Inspection, Maintenance and Adjustment 4-1

Salt Water Areas 3-44

Instrument Panel 2-18, 2-20

Operation of All Switches 4-22

Intermittent Speed Button 2-14

Operation Selection Display 2-46

Operation Under Unusual Conditions 3-42

Operational Checks Before Starting Engine 3-3

Operational Controls and Panels 2-6

Language 2-38

Operator's Area 2-4

Leaks in the Fuel System 4-17

Operator's Compartment Light 2-55

Leaks in the Hydraulic System 4-16

Outer Air Cleaner Element 4-50

Levers

Outer Element of Air Cleaner 4-39

Adjusting Reclining 2-58

Overall Dimensions 7-2

Adjusting the Seat Forward 2-57

Overload Warning Switch (Optional) 2-16

Adjusting the Seat's Angle 2-57

Angle Adjustment of Armrest 2-58

Safety Lever 2-18

Lifting 3-40

Panels

Lifting With Sling 5-5

Air Conditioner Control Panel 2-13

Lights

Audio Control 2-10

Cabin 2-55

Heater and Air Conditioner 2-48

Loading and Unloading 5-1

Heater and Air Conditioner Control Panel 2-49

Locations of Safety Labels 1-4

Instrument 2-18

Long Term Storage 4-85

Instrument Panel 2-20

Lubrication and filters 3-2

Wiper Switch 2-13

Lubrication and Service Chart 4-8

Parking Excavator 3-30

Password

Activated 2-21

Set Password 2-42

Magnetic Clutch 4-58

Password Activated 2-21

Main Menu 2-35

Photo Sensor 2-19

Maintenance in Special Conditions 4-87

Pilot Cutoff Switch 2-55

Maintenance Intervals 4-12

Pilot Filter 4-34, 4-45

Miscellaneous Access Doors 2-68

Pins and Bushings 4-34

Mode Selection 3-19

Power Boost Selection 2-47

Mode Selector Buttons 2-33

Power Mode 3-19

Multifunction Gauge 2-23, 2-27

Power Mode Selection 2-46

Power Mode Selector Button 2-33

Power Socket 2-15

Nuts and Bolts 4-34

Preheating Light 2-26

Preliminary Work Machine Setup for Maintenance

4-4

Oil Cooler Dust Net 4-20

Preventive Maintenance 4-1

Oil Level of Travel Reducer 4-31

Pump Pressure

OP001006 5-1

Front Pump 2-29

Opening the Window 2-62

Rear Pump 2-29

Operating

Controls 2-1

Instructions 3-19

Quick Clamp Switch (Optional) 2-9

Precautions 3-25

Techniques 3-40

Operation 3-1

Radiator Coolant 4-51

Operation In

Rear Hydraulic Pump Pressure 2-29

Extreme Cold 3-42

Refill Cooling System 4-20

Extreme Heat 3-43

Rotating Buttons 2-17

Index

950106-00077E

8-3

Gear and Pinion 4-35

Safety 1-1

Motor 4-84

Safety Lever 2-18, 3-13

Reduction Device 4-19, 4-32, 4-43, 4-49

Safety Precautions 4-3

System 6-4

Seat 2-57

Switches

Seat Adjustment

Auto Idle Selector Button 2-34

Adjusting Reclining 2-58

Automatic Travel Speed Control 3-14

Adjusting the Seat Forward 2-57

Auxiliary Mode 2-9

Adjusting the Seat's Angle 2-57

Booster Button 2-17

Adjustment of Lumbar Support 2-58

Cabin Work Light Switch 2-12

Air Suspension Seat 2-60

Cigar Lighter 2-15

Angle Adjustment of Armrest 2-58

Constant Speed Button 2-14

Headrest 2-58

Display Selector Button 2-36

Left ad Right Control Stand Location 2-60

Down Arrow Button 2-36

Left and Right Control Stand Elevation Height

Economy Mode Selector Button 2-33

2-60

Engine Emergency Stop 2-9

Seat Belt 2-59, 4-22

Engine Speed Control 3-19

Seat Warmer Switch (Optional) 2-16

Engine Speed Control Dial 2-8

Selection Button 2-36

ESC Button 2-37

Selection of

Flow Control Button 2-34

Breaker 2-46

Fuel Heater 2-16

Overload Alarm 2-47

Headlight Switch 2-11

Power Boost Selection 2-46, 2-47

Horn Button 2-17

Shear 2-46

Intermittent Speed Button 2-14

Serial Numbers 4-2

Overload Warning (Optional) 2-16

Set Password 2-42

Pilot Cutoff Switch 2-55

Setting Clock 2-38

Power Mode Selector Button 2-33

Shear Buttons 2-18

Power Socket 2-15

Shimming Procedures for Installed Bucket 4-70

Quick Clamp (Optional) 2-9

Shutdown

Rotating Buttons 2-17

Check and Confirmation After Stopping Engine

Seat Warmer (Optional) 2-16

3-12

Selection Button 2-36

Engine Shutdown 3-11

Shear Buttons 2-18

Parking Excavator 3-30

Starter Switch 2-8

Side Door 2-68

Travel Speed Selector Switch 2-11

Specification 7-1

Travel/Swing Alarm (Optional) 2-15

Standard Mode Selection 2-46

Up Arrow Button 2-35

Standard Specification 7-1

Warning Light 2-12

Starter Switch 2-8

Washer Button 2-14

Starting Engine Using a Booster Battery 3-7

Wiper Switch (Lower) 2-13

Start-up

Symbols

Cold Weather Hydraulic System Warm-up 3-10

Air Cleaner Clogged Warning 2-31

Cold Weather Starting 3-6

Hydraulic Oil Overheat Warning 2-30

Engine Start 3-4

Overload Warning (Optional) 2-32

Hydraulic System Warm-up 3-9

Pilot Filter Clogged Warning 2-30

Inspection Before Starting Engine 3-2

Return Filter Clogged Warning 2-31

Operational Checks Before Starting Engine 3-3

Starting Engine Using a Booster Battery 3-7

Stereo 2-54

Table of Recommended Lubricants 4-6

Audio Control Panel 2-10

Towing Procedure 3-31

Structural Damage 4-55

Track Assemblies 4-26

Suction Strainer 4-53

Track Tension 4-81

Sun Visor 2-66

Transportation 5-1

Swing

Travel 3-14

Bearing 4-25

Index

950106-00077E

8-4

Control Lever Operation 3-15

Instructions 3-16

Warning Light Switch 2-12

Reduction Device 4-31, 4-32, 4-46

Washer Button 2-14

Speed Selector Switch 2-11

Water Separator 4-18

System 6-5

Weight of Workload Materials 7-4

Travel/Swing Alarm Switch (Optional) 2-15

Window Washer Liquid 4-21

Troubleshooting 6-1

Windows

Door Window Holder 2-67

Front 2-62

Unloading and Loading 5-1

Front Bottom 2-63

Up Arrow Button 2-35

Front Upper 2-62

Opening 2-62

Sun Visor 2-66

Wiper Switch (Lower) 2-13

Venting and Priming Hydraulic System 4-83

Wiper Switch Panel 2-13

General Venting 4-84

Work Levers (Joysticks) (ISO Style) 3-22

Hydraulic Cylinders 4-83

Work Light Indicator Light 2-26

Main System Pump 4-83

Working Range 7-3

Swing Motor 4-84

Index

950106-00077E

8-5

Doosan DX300LCA. Operation and Maintenance Manual (2010) - page 3