Doosan DL160. Operation and Maintenance Manual (2008)

Rotate starter key to "O" (OFF) position. Remove key.

FG003900

Figure 21

Hydraulic System Warm-up

Correct operating temperature of hydraulic oil is 50° - 80°C

(120° -

175°F). Make sure to follow procedures listed

below for hydraulic fluid warm-up.

Run engine at idle (no load) for five minutes.

Run engine for approximately five minutes at middle of

speed range, without a load.

Cycle bucket until bucket cylinder bottoms out (extended

and retracted) without a load to circulate the oil through the

system. Do this for five minutes.

NOTE: Do not allow cylinders to pass hydraulic oil over

relief valve for more than twenty seconds at a

time.

Cycle boom, and bucket about five times without a load to

circulate oil through system.

Hydraulic System Warm-up - Cold

Weather

Follow Steps 1 through 3 in "Hydraulic System Warm-up."

Do not operate machine at full speed until system has fully

warmed up.

If working speeds continue to be slow, repeat initial

hydraulic warm-up procedures again. If repeating warm-up

procedures does not improve working speeds, continue to

operate, but use extreme caution because machine

function may be erratic.

Operation

OP000755

3-9

MACHINE TRAVEL

WARNING!

If vehicle is moved while parking brake is engaged,

serious damage to parking brake disk will result.

Select a transmission gear that is appropriate for top

speed that will be traveled. Choosing a gear that is too

high will reduce acceleration and will unnecessarily heat

transmission converter oil.

Never place transmission in "NEUTRAL" when going

down a hill. Over speeding transmission can damage

transmission gears.

Never change direction of vehicle travel at high speed.

Serious damage to transmission will result.

Unlatch frame lock plate between front and rear frames

before traveling. Secure lock plate to rear frame (Figure

22).

FG008052

Figure 22

Set pilot cutoff switch to "I" (UNLOCKED) position. Raise

bucket to a height of 20 - 30 cm (8 - 12 in) above the

ground. Tilt bucket completely back.

HBOI110L

Figure 23

Operation

OP000755

3-10

Set pilot cutoff switch to "O" (LOCKED) position. This will

prevent boom and bucket from accidentally moving during

travel, as a result of accidentally touching pilot control

valve lever (joystick).

HBOI111L

Figure 24

Press brake pedal.

FG002183

Figure 25

Set transmission neutral lock is in the "D"

(DRIVE)

position.

FG003980

Figure 26

Set parking brake switch to the "O" (RELEASE) position.

This will "RELEASE" the parking brake.

HAOP043L

Figure 27

Operation

OP000755

3-11

Place transmission lever in desired gear. Shift gears one

by one. Do not skip from 1st to 3rd, for example.

Shift transmission lever to "FORWARD" position.

FG003979

Figure 28

Release the brake pedal while slowly pressing the

accelerator pedal.

WARNING!

When traveling at high speed or on a steep hill, do

not make sharp changes in direction. This could

cause vehicle to overturn.

When traveling or changing direction, always look

FG003980

carefully to be certain that no one is in path of

Figure 29

vehicle.

Operation

OP000755

3-12

MACHINE SHUT DOWN

Ease off throttle and apply travel brakes.

FG002183

Figure 30

Put transmission lever in "NEUTRAL."

FG003979

Figure 31

Set transmission neutral lock is in the "N"

(NEUTRAL

LOCK) position.

CAUTION!

"LOCK" transmission lever. Whenever machine is

parked, "LOCK" transmission lever in "NEUTRAL"

to prevent accidental machine movement.

FG003980

Figure 32

Set parking brake switch to the "I" (APPLIED) position.

This will ensure that the parking brake is "APPLIED."

HA0O2019

Figure 33

Operation

OP000755

3-13

Set bucket on ground.

Set pilot cutoff switch to "O" (LOCKED) position. This will

lock pilot control valve lever (joystick).

Allow engine to idle for one - two minutes to cool down.

Stopping a turbocharged engine without a cool down

period can seriously damage turbocharger.

HBOI111L

Figure 34

Rotate starter key to "O" (OFF) position. Remove key.

FG003900

Figure 35

If machine is parked on a slope, install wheel chocks in

front of and behind vehicle wheels.

WARNING!

Always secure machine with wheel chocks when

parked on a slope. Leaving machine in gear will

provide no braking effect because transmission

clutch is hydraulically operated. When engine is

turned "OFF," there is no hydraulic pressure in

2876A

transmission and clutch is not engaged.

Figure 36

Operation

OP000755

3-14

BOOM RAISE KICK-OUT

Placing bucket lever in "Boom Raise Detent" position will lock

bucket lever in raise boom position. Boom will raise until trip

plate (1, Figure 37) makes contact with bucket height limit switch

(2). When limit switch is tripped, boom will stop raising and

bucket lever will automatically be returned to "NEUTRAL"

position. Trip plate can be adjusted to control maximum height

that boom can be raised.

FG006218

Figure 37

IMPORTANT

Trip plate (1, Figure 37) must always be set to contact limit

switch

(2) before boom cylinders reach maximum

extension. Maximum extension causes pump to force

fluid over relief valve.

To raise boom to maximum height, past preset height, hold

boom and bucket lever in "Raise" or "Hold Raise" position until

FG006220

boom has reached maximum height. Then remove your hand

Figure 38

from lever. Lever will automatically return to "NEUTRAL"

position. This prevents hydraulic pump from working against

relief valve (maximum pressure).

BUCKET ANGLE INDICATOR

Upper right side of bucket includes a bracket that indicates angle

of bottom of bucket. Top of bracket is parallel with bottom of

bucket. If bottom of bucket is not visible, top of bracket will be

visible.

FG006222

Figure 39

Operation

OP000755

3-15

ADJUSTMENT OF BUCKET

POSITION SWITCH

When bucket lever is held in crowd detent position, after bucket

has been dumped, bucket will pivot toward crowd position. Once

full crowd position has been reached, bucket lever will

automatically return to "NEUTRAL" position. If bucket is lowered

after lever returns to "NEUTRAL," bucket will automatically

position itself to be in a preselected digging position (usually

flat). To adjust bucket to desired preselected digging position,

perform the following steps.

Operate controls to place bucket on ground and in desired

digging position (usually flat). Return bucket lever to its

"NEUTRAL" position.

FG006225

Figure 40

Shut down engine.

Loosen bolts (1, Figure 40) on bracket (2).

Position bracket (2, Figure 40) so that end of arm (3) is

aligned with center of magnetic switch (4).

Tighten bolts (1, Figure 40).

Start engine. Raise boom, dump bucket, then move bucket

lever into crowd detent position. Now lower boom and

check to see that bucket has stopped at required position.

A small readjustment of bracket (2, Figure 40) may be

necessary.

TOWING MACHINE

When necessary to tow another vehicle, the tow rope must be

tied to the towing pin on the counterweight at the rear of vehicle.

NOTE: The loader must be used for towing only in an

emergency.

WARNING!

Do not tow machine at a speed over 10 km/h (6 MPH)

and do not tow machine farther than 10 km (6 mi). This

will prevent damage to machine transmission that would

Figure 41

result from lack of lubrication.

WARNING!

When towing another vehicle on a public road, take

necessary measures to let other vehicles and people

know that you are towing another vehicle. Use a flag,

rotating beacon light, or hazard light.

Operation

OP000755

3-16

NOTE: There are several requirements you must abide by

when towing another vehicle. Learn the regulations

and rules about towing another vehicle and observe

them.

If the loader is being towed by another vehicle and the engine

will not start, remove the front and rear drive shafts; otherwise

the transmission will rotate without being properly lubricated,

causing seizure. Before removing them, apply the parking

brakes and block the wheels securely.

If the engine can be started and the steering wheel and brakes

function normally, have someone get on the loader you are

going to tow for steering it.

Before you tow a vehicle make sure you have checked the

following:

•

Check the weights of your loader and the vehicle to

be towed and make sure you loader has sufficient

braking capacity to stop the towed load.

•

Check if the vehicle to be towed can be braked and

steered. If not, do not allow anyone to ride on the

towed vehicle.

•

Check the tow rope or tow bar for damage and make

sure it has sufficient strength for the work.

•

When necessary to descend a grade, another towing

vehicle must be used in the rear to retard.

When towing make sure you are doing the following:

•

Start slowly. A sudden start can lead to a broken tow

rope.

•

The tow line must be along the center line of both

your loader and the vehicle to be towed.

•

If you use any other towing device, refer to the

Instruction Manual supplied with the towing device.

•

If it is difficult to tow the loader, transport it by a trailer

truck to your nearest repair shop.

•

In addition to the above measures, release the

parking brake if the engine will not start or the

hydraulic pumps are defective.

IF ENGINE STALLS WHILE

TRAVELING

BRAKE SYSTEM: The brakes can be applied approximately 9

times by pressing the brake pedal due to the oil pressure

stored in the accumulator after engine is turned "OFF" if

the engine stalls while traveling, move to an out of traffic

area and park. Do not pump the brake pedal at this time;

otherwise the brake oil pressure will be used up, thus

causing the brakes to fail.

Operation

OP000755

3-17

ALLOWABLE WATER DEPTH

The water depth is an important factor to take into consideration

when the loader is working in swampy areas. Do not enter water

whose depth exceeds the loader's minimum ground clearance

height or is high enough to wet the bottom of the axle housing.

As a rule of thumb, the allowable water depth is about 400 mm.

This means that the loader should not be used in a river.

Observe the following conditions:

Check the water depth in advance when crossing across a

river.

Use the same precautions before crossing across a

swampy area.

Do not enter rivers whose river bed is steep or has a rapid

flow.

CAUTION!

Avoid use of the loader in salt water. Salt water

will cause the development of rust which will

shorten the life of the loader.

Operation

OP000755

3-18

OP000756

4Inspection, Maintenance

and Adjustment

BASIC PREVENTIVE

MAINTENANCE

For the machine to function satisfactorily and at lowest possible

cost, a thorough maintenance program is required. This section

of the manual describes the maintenance work which the

operator can carry out. If certain operations require trained

workshop personnel and special equipment, this will be

indicated.

The intervals recommended between checks, oil changes and

lubrication apply provided that the machine is used under

normal environmental and operating conditions. See

“Lubrication and Service Chart” on page 4-17

Arrival and Delivery Inspection

Before the machine leaves the factory, it is tested and adjusted.

The dealer must also, if the warranty is to apply, carry out

"Arrival and Delivery Inspections" according to applicable form,

which must be signed.

Delivery Instructions

Figure 1

When handing the machine over, the dealer must give the buyer

"Delivery Instructions" according to applicable form, which must

be signed, if the warranty is to apply.

Inspection, Maintenance and Adjustment

OP000756

4-1

Service Points

11 14

FG013060

Figure 2

Reference

Description

Number

Level Sight Gauge Hydraulic Oil

Draining, Engine Oil

Breather of Hydraulic Oil

Filling Point, Engine

Air Cleaner

Main Fuel Filter

Pre Cleaner

Battery

Filling Point, Fuel

Return Oil Filter

Draining, Coolant

Filling Point, Coolant

Pre Fuel Filter

Filing Point, Washer Fluid

Filling Point, Transmission

Filling Point, Hydraulic Oil

Draining, Hydraulic Oil

Ventilation Filters, Cabin

Pilot Filter

Alternator Belt

Oil Dipstick

Suction Strainer, Transmission

Oil Filter, Engine

Oil Filter, Transmission

Inspection, Maintenance and Adjustment

OP000756

4-3

SAFETY WHEN SERVICING

This section deals with the safety rules which must be followed

when checking and servicing the machine. DOOSAN disclaims

all responsibility if other tools, lifting devices or working methods

are used other than those described in this publication.

Further safety rules and information and warning texts are given

within the respective section.

NOTE: Lifting with a jack must only be carried out by trained

personnel.

WARNING!

If work has to be carried out on the machine before it

has cooled down, care must be observed with regard to

risk of burns from hot liquids and hot machine parts.

Inspection, Maintenance and Adjustment

OP000756

4-4

Service Position

BEFORE beginning service work the machine must be parked

on level ground and positioned as shown below.

AFTER completing the service, all guards must be installed and

all engine covers must be closed and locked.

FG013061

Figure 3

Reference

Description

Number

The bucket/attachment must be resting on the ground.

Apply the parking brake.

Shut down engine and take out the ignition key. (Does not apply when checking oil

level in transmission).

Carefully release the pressure in pressure lines and pressure vessels to avoid risks.

Attach a black and yellow "Warning Tag" to the steering wheel.

Connect the frame joint lock.

Block the wheels in a suitable way (with, for example, wedges).

Allow the machine to cool.

Inspection, Maintenance and Adjustment

OP000756

4-5

Before Service Read

•

Read the Operator's Manual and the decals/labels

and instructions found on the machine to obtain the

required knowledge and information about the

machine.

•

To be able to carry out the service work in a correct

way, it is important that the correct tools and

equipment be used. Replace or repair broken tools

and faulty equipment.

•

When lifting the machine, the frame joint must be

locked and the machine lifted at the eyes intended for

this purpose. See “Summary of Safety Precautions

for Lifting” on page 5-2

Figure 4

•

Use a hard hat, safety glasses, protective shoes and

gloves and an approved respirator or other protective

articles when required.

•

Do not wear loose fitting clothing or jewelry.

•

Keep service surfaces and handholds clean from oil,

dirt and ice.

Figure 5

•

Use the stepping areas provided with antislip

protection to avoid the risk of slipping. Worn, painted

over, or loose protections must be replaced.

Remember that high-pressure water jets when

washing and spilled oil can cause the protections to

loosen. Do not direct the water jet against the

protections and wipe up spilled oil.

•

Make sure that there is sufficient ventilation when

starting the engine indoors.

•

Do not exceed the maximum permissible floor load.

FG008056

•

Do not stand in front of or behind the machine while

Figure 6

the engine is running.

•

Use a ladder when changing light bulbs or carrying

out other service work high up on the machine.

•

Use a long handled window scraper and brush or a

ladder when cleaning the outside of the windows.

Inspection, Maintenance and Adjustment

OP000756

4-6

•

The installation of two-way radio, lever steering or

similar equipment must be carried out by a skilled

person, as faulty installation may cause interference

with the electronic components controlling vital

machine functions.

•

When carrying out service work below raised lifting

arm system, the lifting arms must first have been

secured (lifting arm support). In addition the control

lever lockout and the parking brake must be applied.

•

Take care when changing oil in engine, hydraulic

system or transmission as the oil may be hot and

cause burns.

•

When emptying/draining oil or fuel, use a pump or a

hose and collect the liquids in a suitable vessel.

Spillage will damage the environment and may cause

a fire. Waste oil and other contaminating liquids must

be taken care of by a firm especially authorized to

carry out such work.

•

When operating in an area which is contaminated or

dangerous to one's health, the machine must be

especially equipped for this purpose. Special local

safety regulations apply within such areas and also

when servicing the machine.

•

Shut down engine before opening engine covers etc.

Make sure that no tools or other objects, which may

cause damage, have been forgotten in or on the

machine.

•

Check that the equipment you are using for lifting or

supporting parts of the machine, e.g. straps, slings,

ratchet blocks and ground support, can safely cope

with the strain they are exposed to and meet

applicable regulations.

•

Release the pressure in pressure vessels,

components and systems carefully and in the

prescribed way, so that the excess pressure is

released without risk.

•

When connecting hydraulic hoses, check that the

desired effect has been achieved, that is, check that

the hydraulic function operates in the expected way.

•

Hoses, pipes and quick-connect couplings may be

pressurized even if the machine is stationary and the

engine turned "OFF." Such pipes and hoses should

therefore only be disconnected by trained personnel.

•

When looking for leaks, use a piece of paper or

wood, not your hand.

Inspection, Maintenance and Adjustment

OP000756

4-7

Fire Prevention Measures

There is always a risk of fire. It is important that you use a fire

extinguisher that suits your machine and working environment

and that you learn how to use it. The fire extinguisher must be

placed behind the seat or externally in a lockable box.

If the machine is to be provided with a handheld fire extinguisher, it

must be of the ABE type (ABC in the USA), which means that it

is possible to extinguish fires in both solid and liquid carbonaceous

material and that the active compound does not conduct

FG003902

electricity.

Figure 7

The effectiveness grade I means that the time the extinguisher is

effective must not be less that eight seconds, grade II at least

eleven seconds and grade III at least fifteen seconds.

A handheld fire extinguisher ABE I (in the USA ABC type)

normally corresponds to a powder content of

4 kg (8.8 lb)

(EN-grade 13A89BC), the EN 3-1995 standard, parts 1, 2, 4 and

At the slightest sign of fire, and if the situation allows, take the

following steps:

Drive the machine away from the fire sensitive area

caused by the fire.

Lower the lifting arms to the ground.

Shut down engine by turning the ignition key to the "0"

(OFF) position.

Leave the cabin.

Turn off the battery disconnect switch.

Start putting out the fire and notify the fire brigade/

department if necessary.

It is forbidden to smoke or have an open flame near a machine

when filling with fuel or when the fuel system has been opened

and in contact with the surrounding air.

Diesel fuel oil is flammable and must not be used for cleaning.

Use an approved solvent and do not inhale the fumes. Also bear

in mind that certain solvents can cause skin rashes and

constitute a fire hazard.

Flammable starting must not be used due to the use of the

electric preheating in the induction air system.

Keep the place clean where the service is to be carried out. Oil

or water makes the floor slippery and is also dangerous in

connection with electrical equipment or electrically powered

tools. Oily or greasy clothes are a serious fire hazard.

Check daily that the machine and the equipment, e.g.

underbody plates are free from dust and oil. In this way the risk

of fire is reduced and it is easier to detect faulty or loose components.

NOTE: If a high-pressure jet is used for cleaning, take great

care as the insulation of electric leads can be

damaged even at a moderately high-pressure and

Inspection, Maintenance and Adjustment

OP000756

4-8

temperature. Protect electrical leads in an

appropriate way.

Take extra care when cleaning the machine after it has been used

in a fire sensitive environment, e.g. sawmill and refuse dumps.

Reduce the risk of spontaneous combustion by installing for

example silencer guard or high capacity cyclone precleaner.

Sound absorbing material in the engine compartment must be

kept clean to minimize the fire hazard.

Fire prevention equipment which is installed on the machine

must be maintained and regarded as a complement to the

actions of the operator in case of a fire.

Check that fuel lines, hydraulic and brake hoses and electrical

cables have not been damaged by chafing or are not in danger

of being damaged because of incorrect installation or clamping.

This applies particularly to unfused cables, which are red and

marked R(B+) and routed:

•

between the batteries

•

between battery and starter motor

•

between alternator and starter motor

•

to the preheating element on the engine.

Electrical cables must not lie directly against oil or fuel lines.

The following applies for welding and grinding work:

•

A fire extinguisher must be kept near at hand.

•

The ventilation must be good when working indoors.

•

Approved respirator must be used

•

The work surface must be cleaned.

•

Do not weld or grind on components which are filled

with flammable liquids, e.g. tanks and hydraulic

pipes. Exercise care with such work in the proximity

of these places.

Working on Painted Surfaces

When welding, grinding and gas cutting, the paint finish must

first be removed from an area with a radius of at least 10 cm

(4 in) from the point where the work is to be carried out. The

reason for this is that paint when heated gives off a great

number of different substances which can cause irritation and be

very harmful to a person's health in case of long or frequent

exposure.

In addition to the health hazard, the weld will also be of an

inferior quality and strength, which in the future may cause the

weld to break. Therefore, never weld directly on a painted surface.

Inspection, Maintenance and Adjustment

OP000756

4-9

Methods and Precautionary Measures

When Removing Paint:

Blasting

•

use respirator and eye protection

Paint remover or other chemicals

•

use a portable air extractor, respirator and protective

gloves

Grinding machine

•

use a portable air extractor, respirator and protective

gloves and eye protection

Floor Rubber

Observe extra great care when it is suspected that you may

have to handle floor rubber.

Certain seals which have to withstand high operating

temperatures (e.g. in engines, transmissions, axles, hydraulic

motors and pumps) may be made from floor rubber, which,

when exposed to high heat (fire), forms hydrogen fluoride and

hydrofluoric acid. This acid is very corrosive and cannot be

rinsed or washed off from the skin. It causes very severe burns

which take a long time to heal.

It usually means that damaged tissue must be surgically

removed. Several hours may pass after contact with the acid,

before any symptoms appear and therefore one is not given any

immediate warning. The acid may remain on the machine parts

for several years after a fire.

If swelling, redness or a stinging feeling appears and one

suspects that the cause may be contact with heated floor rubber,

contact a medical doctor immediately. If a machine, or part of a

machine, has been exposed to fire or severe heat, it must be

handled by specially trained personnel. In all handling of

machines after a fire, thick rubber gloves and effective goggles

must be used.

The area around a part which has been very hot and which may

be made of floor rubber must be decontaminated by thorough

and ample washing with lime water (a solution or suspension of

calcium hydroxide, i.e. slaked lime in water). After the work has

been completed, gloves must be washed in lime water and then

discarded.

Inspection, Maintenance and Adjustment

OP000756

4-10

Rubber and Plastics

Polymer materials when heated, can form compounds which are

dangerous to health and environment and must therefore never

be burned when scrapped. Also take care when handling

machines which have been subjected to fire or other extreme

heat.

If gas cutting or welding is to be carried out near such materials,

the following safety instructions must be followed:

•

Protect the material from heat.

•

Use protective gloves, protective goggles and an

approved respirator.

Waste Hazardous to the Environment

Painted parts or parts made of plastic or rubber which are to be

scrapped must never be burnt, but must be taken care of by an

approved refuse handling plant.

Batteries, plastic objects and anything else which is suspected

of being dangerous to the environment must be taken care of in

an environmentally safe way.

Check List After Fire

When handling a machine which has been damaged by fire

or been exposed to intense heat, the following protective

measures must under all circumstances be followed:

Use thick, gloves made of rubber and wear goggles which are

certain to protect your eyes.

Never touch burnt components with your bare hands, as there is

a risk that you may come into contact with melted polymer

materials. First wash thoroughly with plenty of lime water (a

solution or suspension of calcium hydroxide, i.e. slaked lime in

water).

As a precaution, seals (O-rings and other oil seals) should

always be handled as if they were made of floor rubber.

Treat skin, which is suspected of having come into contact with

burnt floor rubber, with Hydrofluoric Acid Burn Jelly or something

similar. Seek medical advice. Symptom may not appear until

several hours afterwards.

Discard gloves, rags etc. which are suspected of having come

into contact with burnt floor rubber.

Inspection, Maintenance and Adjustment

OP000756

4-11

PREVENTIVE MAINTENANCE

Periodic checks and replacement of oil, grease, filters, etc. must

be made at specific intervals, to keep machine in good working

condition. The following pages describe items to be checked,

lubricants to be used, and time interval between each check.

NOTE: Time interval between each service check may need

to be shortened if machine is operating in severe

atmospheric conditions. Machines working in

extremely hot or dusty conditions will require more

frequent service checks. Total hours of machine

operation are determined by hour meter that is on the

front instrument panel.

HAOA600L

Figure 8

Product Identification Number (P. I. N.)

Location

The PIN is stamped on the product identification plate (Figure 9)

on the right side of front frame above wheel cover.

NOTE: Please make note of these numbers and their

locations. These will be required whenever warranty

or service work is requested. Keep this number on

file, in case the mathine is stolen.

Doosan Infracore Co., Ltd.

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

Incheon, Korea

FG013062

Figure 9

Inspection, Maintenance and Adjustment

OP000756

4-12

The number is also stamped in the rear frame on the left side

just below the cabin (Figure 10).

FG008058

Figure 10

Engine Serial Number

The engine name plate

(identification label) is attached to

engine headcover (1, Figure 11). The engine serial number is

stamped on the right rear of the engine block, under exhaust

manifold (2, Figure 11).

FG006234

Figure 11

Safety Precautions

Before performing any maintenance checks, move pilot

cutoff switch to "LOCKED" position. Place a Warning Tag

on controls so that no one begins to operate machine while

maintenance checks are being performed.

Clean up all fuel spills. Fuel spills are hazardous,

especially around engine.

Inspect all fuel lines for leakage. Replace any lines, fittings,

O-rings, or filters that show signs of wear or damage.

If a test procedure requires engine to be running, use two

people and keep all unnecessary personnel away from

machine.

Inspection, Maintenance and Adjustment

OP000756

4-13

TABLE OF RECOMMENDED

LUBRICANTS

IMPORTANT

Do not use lubricants other than those recommended,

without prior written approval from DOOSAN.

NOTE: Refer to the Maintenance Intervals Table for

application points.

LUBRICANT

HYDRAULIC OIL

ENGINE OIL

AXLE GEAR OIL

MANUFACTURER

GREASE

TOTAL

TOTAL EQUIVIS

TOTAL

RUBIA

TOTAL MULTIS

ZS 46 IV

TIR 7400 10W40

EP #2

TOTAL

RUBIA

POLYTRAFIC

10W40

TOTAL

RUBIA

8600 10W40

GS-CALTEX

RANDO HD CZ

SIGMA DX-1

MULTIFAK EP #2

10W40

CHEVRON

AW 32 (BELOW

DELO 400 15W40

DELO GREASE

DELO GEAR OIL

0°C)

EP #2

or RPM UNIV

GEAR 80W90

(ABOVE

0°C)

TEXACO

RANDO HDZ 46

URSA SUPER

MULTIFAK ALL

MULTI-GEAR EP

PREMIUM 15W40

PURPOSE EP #2

SAE 80W90

ESSO

UNIVIS N 46

ESSOLUBE XT-5

RONEX MP

SPARTAN EP220

15W40

or EXXON GX

80W90

MOBIL

MOBIL DTE 13M

MOBIL DELVAC

RONEX MP

LUBE SHC LS

MX 15W40

15W90 or SAE

75W90LS

SHELL

TELLUS OIL T 46

RIMULA ULTRA

ALVANIA EP #2

SPIRAY HD

10W40

85W90 or LS 90

PENNZOIL

MULTIPURPOSE

MULTI-PURPOSE

WHITE GREASE

4092 or 80W90

705 EP #2

CASTROL

PARADENE AW

CASTROL EPL #2

LSC SAE 90

32 (BELOW 0°C)

PARADENE AW

46 (ABOVE 0°C)

Inspection, Maintenance and Adjustment

OP000756

4-14

LUBRICANT

HYDRAULIC OIL

ENGINE OIL

AXLE GEAR OIL

MANUFACTURER

GREASE

IDEMITSU KOSAN

DAPHNE KOSAN

DAPHNE

APOROIL GEAR

32 WR (BELOW

EXPONES SR #2

AE 90

0°C)

DAPHNE KOSAN

46 WR

(ABOVE

0°C)

DRYDEN

AP 80W90

NIPPON SEIKIYU

NISEKI SP90 or

EP90

FUCHS

RENO GEAR OIL

LSA SAE 90 or

TITAN GEAR

85W90 LS

LUBRICANT

TRANSMISSION GEAR OIL

MANUFACTURER

Same as engine oil

SAE 15W40

API CD and above

Antifreeze

Recommended Concentration

Manufacturers Meeting ASTM D3306

Dexcool ELC by Chevron Texaco

50% Antifreeze - 50% Distilled Water

Alugard G48 by BASF

Others meeting or exceeding ASTM D3306

CAUTION!

Do not mix oils from different manufacturers. DOOSAN

does not endorse specific brands but does suggest that

owners select quality oils whose suppliers provide

assurance that required standards will always be met or

exceeded.

IMPORTANT

Fluctuating daily or weekly extremes of temperature, or

operation in subzero freezing weather may make it

impractical to use straight weight lubricants. Use good

judgement in selecting lubricant types that are

appropriate for climate conditions.

Inspection, Maintenance and Adjustment

OP000756

4-15

QSB4.5 Industrial Engines Oil Drain

Intervals by Duty Cycle (Hours)

Heavy

ACEA E5 (API CI-4)

500

CES 20078

NOTE:

Limit oil change interval to

250 hour maximum for oil grades if 40% of the operating time is in

ambient temperatures above 38°C (100°F) to prevent engine damage to oil degradation resulting

from high oil temperature.

We don't recommend the use of CF or CG grade oils. If CF or CG oils must be used, make the

oil drain intervals half of the API CI-4 values.

Engine oil drain intervals need to be reduced by

50% when fuel sulfur content exceeds 0.5%

(5000 ppm).

FLUID CAPACITIES

Component

Capacity

Engine

QSB 4.5

11 liters

(2.9 U.S. gal.)

Oil Pan with Filter

Engine

NOTE: The filter holds an additional 1 liter (1 qt) of oil.

8.5 liters

Cooling System

(2.2 U.S. gal.)

185 liters

Fuel Tank

(48.9 U.S. gal.)

100 liters

Hydraulic Oil Tank

(26.4 U.S. gal.)

21 liters

Transmission

(5.5 U.S. gal.)

15.0 liters

7.5 liters

Front / Rear Differential

(4.0 U.S. gal.)

(2.0 U.S. gal.)

Axles

1.7 liters

1.25 liters

Front / Rear Planetaries

(0.45 U.S. gal.)

(0.33 U.S. gal.)

Inspection, Maintenance and Adjustment

OP000756

4-16

LUBRICATION AND SERVICE

CHART

Greasing Bearing

The service life of bushings and pivot pins can be extended

considerably, if the machine is greased regularly and in the

correct way.

The greasing of bearings has two main purposes:

•

Add grease to the bearing to reduce friction between

pin and bushing.

•

Replace old grease which may contain dirt. The

grease in the space inside the outer seal collects dirt

and prevents dirt and also water from penetrating into

the bearing.

Therefore, grease the bearing until new, clean grease is forced

out through the outer seal.

Between 10 and 15 strokes with a normal handheld grease gun

is required to grease one of the bearings for the lifting arms.

Wipe off grease fittings and grease gun before greasing, so that

dirt and sand is not introduced through the grease fittings.

Symbol key

These standard symbols are used in “Lubrication and Service

Chart” on page 4-18.

Symbol

Description

Symbol

Description

Lubrication

Air Cleaner Element

Transmission Oil

Fuel Filter

Engine Oil

Air Conditioner Filter

Engine Oil Filter

Drain Water

Hydraulic Oil

Gear Oil (Axle)

Hydraulic Oil Return Filter

Brake Filter

Coolant

Level Check

Inspection, Maintenance and Adjustment

OP000756

4-17

Service Data

Service Interval

No.

Items To Check

Service

Qty.

250

500

1000

1500

2000

Front Joint Pin

Grease

F100

W10

Articulation Pin

Grease

Rear Axle Pivot

Grease

Steering Cylinder

Grease

Front Drive Shaft

Grease

Bearing

Fuel Tank

Diesel

185 L

Hydraulic

Hydraulic Oil Tank

100 L

Oil

Engine Oil

Engine Oil Pan

11 L

15W40

Coolant

Radiator

44 L

(Antifreeze)

Axle Gear

Front Axle

Oil

15 L

(80W90)

Axle Gear

Rear Axle

Oil

7.5 L

(80W90)

Engine Oil

Transmission

21 L

15W40

Pre

Fuel Filter

Cartridge

Main

Engine Oil Filter

Cartridge

Transmission Filter

Cartridge

Full Flow Filter

Element

Oil Suction Strainer

Strainer

Brake and Pilot Filter

Element

(Outer)

Air Cleaner

Element

(Inner)

Air Intake Precleaner

Case

Air

Outer

Conditioner

Cartridge

Inner

Filter

V: Maintenance and Refill.

C: Cleaning.

F: First Time Exchange Only.

F100: Every 10 Hours for First 100 Hours.

W10: Every 10 Hours If Operating In Water.

EG: Ethylene Glycol - Standard Life Antifreeze (Drain and replace using this interval.) See “Engine Cooling

System” on page 4-72, for further explanation.

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

System” on page 4-72, for further explanation.

Gray Box: Replacement On Every Interval.

NOTE: For additional service items see list of “Maintenance Intervals” on page 4-20.

Inspection, Maintenance and Adjustment

OP000756

4-19

MAINTENANCE INTERVALS

SERVICE ITEM

PAGE

10 Hour / Daily Service

Grease Front Attachment Pins (for First 100 Hours)

4-22

Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear

4-22

Check Engine Oil Level

4-22

Check Transmission Oil Level

4-23

Check Hydraulic System Oil Level

4-24

Check for Leaks in Hydraulic System

4-25

Fill Fuel Tank

4-25

Check for Leaks in Fuel System

4-26

Drain Fuel Condensation

4-26

Check Coolant Level

4-26

Check Level of Windshield Washer Liquid

4-27

Inspect the Bucket Teeth and Side Cutters for Signs of Wear

4-27

Inspect Seat Belt for Proper Operation

4-27

Inspect the Structure for Cracks and Faulty Welds

4-27

Check the Operation of All Switches

4-27

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

4-28

Lights

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

4-28

Operating Temperature. Listen for Any Abnormal Sounds

Check Operation of All Controls

4-28

Inspect Cooling Fan Blade

4-29

Check Engine Drive Belt Wear

4-29

Check Air Intake System

4-30

50 Hour / Weekly Service

Perform All Daily, 10 Hour Service Checks

4-31

Grease Front Attachment Pins

4-31

Grease Upper and Lower Center Pins

4-35

Replace Engine Oil and Filter (After First 50 Hours)

4-35

Replace Hydraulic Full Flow Filter (After First 50 Hours)

4-36

Check Air Conditioner and Alternator Belt Tension (After First 50 Hours)

4-36

Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser

4-36

Clean Air Conditioner Outer Filter

4-37

250 Hour / Monthly Service

Perform All Daily, 10 Hour and 50 Hour Service Checks

4-38

Check Engine Air Intake Precleaner

4-38

Drain Water from Hydraulic Oil Tank

4-38

Turbocharger

4-39

Check Air-Conditioner and Alternator Belt Tension

4-39

Grease Drive Shaft

4-40

Replace Transmission Oil and Filter (After First 250 Hours)

4-40

Inspection, Maintenance and Adjustment

OP000756

4-20

Replace Axle Differential and Planetaries Oil (After First 250 Hours)

4-40

Clean Outer Filter of Air Cleaner

4-41

Water Trap

4-42

500 Hour / 3 Month Service

Perform All Daily, 10, 50 and 250 Hour Service Checks

4-43

Replace Hydraulic System Brake and Pilot Filter

4-43

Replace Fuel Prefilter

4-44

Fuel Filter (Spin-On Type)

4-45

Replace Fuel Filter

4-46

Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser

4-46

Clean Air Conditioner Inner Filter

4-47

Replace Engine Oil and Filter

4-48

Replace Air Conditioner Outer Filter

4-49

1,000 Hour / 6 Month Service

Perform All Daily, 10, 50, 250 and 500 Hour Service Checks

4-50

Air Cleaner

4-50

Replace Outer Air Cleaner Element

4-51

Drain and Replace Transmission Oil and Filter

4-52

Clean Fuel Tank and Strainer

4-54

Replace Air Conditioner Inner Filter

4-55

Check Air Conditioner Refrigerant

4-55

Check and Adjust Engine

4-56

Replace Hydraulic Full Flow Filter

4-57

1,500 Hour / 9 Month Service

Perform All Daily, 10, 50, 250 and 500 Hour Service Checks

4-59

Replace Axle Differential and Planetaries Oil

4-59

Axle Brake Disk Wear Measurement

4-60

2,000 Hour / Yearly Service

Perform All Daily, 10, 50, 250, 500 and 1,000 Hour Service Checks

4-61

Replace Inner Air Cleaner Element

4-61

Check Steering, Brake, Drive Shaft, Engine, and Fuel System

4-61

Replace Pipes and Hoses

4-62

Bleed Brakes

4-62

Replace Radiator Coolant

4-63

Replace Hydraulic Oil and Clean Oil Suction Strainer

4-64

Check Brake Accumulator

4-66

12,000 Hour / Six Year Service

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

CEN)

4-67

Inspection, Maintenance and Adjustment

OP000756

4-21

10 HOUR / DAILY SERVICE

Grease Front Attachment Pins

(for First 100 Hours)

NOTE: Fittings are greased daily, or every 10 hours, for the

first

100 hours of operation to comply with new

machine break-in requirements. After that, greasing

must be done every 50 hours. If bucket is being used

in water, grease fittings immediately after machine is

removed from water. Follow procedure printed under

the

50 hour maintenance interval

“Grease Front

Attachment Pins” on page 4-31.

Inspect All Tires for Correct Tire Pressure

and Signs of Damage or Abnormal Wear

Inflate tires to proper operating pressure for working

conditions. See “Tires” on page 4-83

Check Engine Oil Level

NOTE: When checking level using a dipstick always remove

and wipe it clean before making final level check.

Check level of engine oil every day before starting engine.

FG013906

Figure 13

Remove engine oil dipstick (1, Figure 13). Oil level must be

between "LOW" and "FULL" marks.

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

must be drained to return oil to proper level.

To add oil, remove engine oil fill cap (2, Figure 13).

HAOC280L

Figure 14

Inspection, Maintenance and Adjustment

OP000756

4-22

Check Transmission Oil Level

NOTE: When checking level using a dipstick always remove

and wipe it clean before making final level check.

Use two people to perform this operation.

Start machine and drive it until transmission fluid has

warmed to 80°C (176°F). Park machine on firm, level

ground. Lower bucket to ground.

Place transmission lever in "NEUTRAL." Apply parking

brake. Shut down engine.

FG008085

Figure 15

Block tires. Once tires are blocked, start engine and have a

person remain in the cabin.

Allow engine to idle until transmission temperature is to

80°C (176°F).

Remove transmission dipstick (Figure 16). Wipe dipstick

clean and then insert it back into transmission.

Remove dipstick and check oil level mark. Oil level must be

between "LOW" and "FULL" marks.

To add oil, remove transmission fill cap (Figure 15) from

transmission oil filter pipe.

Shut down engine when done.

HAOC280L

Figure 16

Inspection, Maintenance and Adjustment

OP000756

4-23

Check Hydraulic System Oil Level

WARNING!

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool before attempting to

service any of the hydraulic components.

The hydraulic tank is pressurized. Loosen the cap of

breather 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.

Move machine to a level area and shut down engine.

Apply parking brake.

Lower bucket to ground.

Check sight gauge (Figure 17) that is attached to hydraulic

oil tank. Oil level must be between upper limit and lower

limit shown on gauge.

NOTE: Hydraulic oil tank is located in front frame.

Figure 17

To add hydraulic oil, remove the air breather cap (Figure

18).

Add oil through the air breather cap to proper level by

checking sight glass (Figure 17).

IMPORTANT

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

Overfilling can result in damage to equipment and oil

leaking from hydraulic tank due to expansion.

Figure 18

The hydraulic oil fill cover also serves as the hydraulic oil

strainer access cover. It is important to replace this cover and

the components in the proper order and alignment.

The filter (2, Figure 19), retaining rod (3) and spring (4) are

assembled as shown in Figure 19. The hole (1) in the base of

the filter fits over a circular base in the bottom of the tank. The

retaining rod (3) screws into the top of the filter (2), but the

spring (4) slides over the top of the rod. Be certain that this

spring does not fall into the tank during reassembly.

If filter assembly was removed, insert assembly into the

FG002188

tank and check to make sure it is securely in place.

Figure 19

Check O-ring for damages and replace if necessary.

Check position of O-ring at surface of hole.

Inspection, Maintenance and Adjustment

OP000756

4-24

Place the cover on the access hole. Make sure the spring

retaining cup (1, Figure 20) in the lower section of the

cover is lined up with the spring. The filter assembly rod

must be in a vertical position and perpendicular to the base

of the tank. The cover can be rotated to align the rod into a

vertical position.

Tighten mounting bolts to 4.84 kg•m (35 ft lb).

FG002189

Figure 20

Check for Leaks in Hydraulic System

Perform a daily walk-around inspection to make sure that

the hoses, piping, fittings, cylinders and hydraulic motors

are not showing any signs of leakage. If any is noted,

determine the source of the leak and repair.

Fill Fuel Tank

WARNING!

Use extreme safety precautions while refueling to prevent

explosions or fire.

Immediately clean up any spilt fuel.

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

FG013800

Figure 21

fill cap (Figure 21). When working at a temperature of 0°C

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

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

equivalent.

Securely tighten cap after fueling.

NOTE: If breather holes in cap are clogged, a vacuum

may form in the tank preventing proper fuel flow

to engine. Keep holes in fuel cap clean.

FG001690

Figure 22

Inspection, Maintenance and Adjustment

OP000756

4-25

Check for Leaks in Fuel System

Perform an inspection of engine compartment to verify that

fuel system is not leaking. If any is noted, determine the

source of leak and repair.

Drain Fuel Condensation

Open fuel tank drain valve.

(Figure

23). Allow any

condensed water or sediment to drain out of tank.

NOTE: Dispose of drained fluids according to local

regulations.

Figure 23

Check Coolant Level

NOTE: Do not mix ethylene glycol and propylene glycol

antifreeze together. If the two are mixed, the

protection level will be reduced to the level of the

ethylene glycol.

NOTE: This unit was factory filled with propylene glycol.

WARNING!

FG001692

Figure 24

Never open radiator when it is hot. Scalding liquid

inside a hot radiator is under pressure. Removing cap

from a hot radiator could cause a person to be sprayed

and burned from liquid inside. Wait for radiator

temperature to cool down before removing cap.

Check sight gauge (1, Figure 25) that is attached to the

radiator. Coolant level must be visible in red centered circle

shown on gauge. To add coolant, remove fill cap (2, Figure

25) of the radiator and add coolant to proper level by

checking sight gauge (1, Figure

25). If temperature is

below freezing, see “Antifreeze Concentration Tables” on

page 4-73 for antifreeze protection. Use the table to

calculate a proper mixture of antifreeze and water to

provide level of protection necessary for expected

temperature.

FG006258

Figure 25

Inspection, Maintenance and Adjustment

OP000756

4-26

Check Level of Windshield Washer Liquid

Check fluid level in windshield washer tank, behind

operator's seat.

Open fill cap and add fluid.

NOTE: Use a washer liquid that is rated for all seasons.

The will prevent freezing during cold weather

operation.

FG001693

Figure 26

Inspect the Bucket Teeth and Side Cutters

for Signs of Wear

On a daily 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 the

point that bucket base edge is exposed. (Figure 27)

NOTE: These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers'

buckets, refer to their specific instructions.

Figure 27

Inspect Seat Belt for Proper Operation

Inspect the Structure for Cracks and

Faulty Welds

During the daily walk-around inspection and when

greasing the machine, look for any visible damage to the

machine. Repair or replace any damaged parts before

operating machine.

Check the Operation of All Switches

Verify working condition of all switches before starting

engine.

Inspection, Maintenance and Adjustment

OP000756

4-27

Check the Operation of All Exterior Lights,

Horn and Control Console Indicator

and Monitor Lights

Turn engine starter switch to "I" (ON) position and observe

all indicator lights.

Restore operation of any light bulbs that do not turn "ON"

at this time.

Sound the horn. Repair or replace if required.

Turn "ON" and inspect all exterior work lights. Replace any

monitors, burned out bulbs or cracked or broken housings

or lenses.

Start Engine, Check Starting Ability, and

Observe Exhaust Color at Start-up and

at Normal Operating Temperature.

Listen for Any Abnormal Sounds

Check Operation of All Controls

IMPORTANT

Cold weather operation requires that the operator fully

warm up the hydraulic oil before beginning machine

operation. Follow all warm up instructions listed in the

Operating Instruction section of this manual. Make sure

to cycle oil through all of the components, including all

cylinders, both travel motors and the swing motor. Cold

hydraulic oil in the lines and components needs to be

warmed before beginning full operation. If this is not

done, damage to the cylinders or hydraulic motors can

occur.

With engine at rated speed, operate all of the controls.

Follow cold weather hydraulic system warm-up

procedures.

Note any slow operations or unusual movements.

Determine the cause and repair fault before operating.

Inspection, Maintenance and Adjustment

OP000756

4-28

Inspect Cooling Fan Blade

WARNING!

Personal injury can result from a fan blade failure.

Never pull or pry on the fan. This can damage the fan

blade(s) and cause fan failure.

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

cracks, loose rivets, bent or loose blades, and for contact

Figure 28

between the blade tips and the fan shroud. Check the fan

to make sure it is securely mounted. Tighten the bolts if

necessary. Replace any fan that is damage.

NOTE: Please stop the engine before checking the

blades in order to prevent any injury by the fan

rotation.

Check Engine Drive 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.

WARNING!

Figure 29

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 "O"

(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

Inspection, Maintenance and Adjustment

OP000756

4-29

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 20 hour intervals until tension is

stabilized and thereafter, every 250 hours. If the tension

falls below the required minimum, the belt will be able to

slip, damaging the belts and pulley grooves.

NOTE: When operating in abrasive conditions, check

tension every 100 hours.

Check Air Intake System

WARNING!

Hot engine components can cause burns.

Avoid contact with hot engine components.

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground, and shut down

HAOA050L

engine.

Figure 30

Check the engine intake hose, and hose clamps for

damage and tightness.

If damaged, wrinkled or loose, replace, tighten or contact

your nearest DOOSAN loader dealer.

IMPORTANT

Severe engine damage will result from running with

unfiltered air.

Do not operate engine if any leaks or defects are

Figure 31

found on air intake system.

Inspection, Maintenance and Adjustment

OP000756

4-30

50 HOUR / WEEKLY SERVICE

Perform All Daily, 10 Hour Service Checks

Grease Front Attachment Pins

Following fittings are greased daily, or every 10 hours, for

first

100 hours of operation to comply with new machine

break-in requirements. After that, greasing should be done

every 50 hours. If bucket is being used in water, grease

fittings immediately after machine is removed from water.

H1 - H3

J K

FG013066

Figure 32

A. Bucket hinge pins, 2 locations (1 each side) (Figure

33).

Figure 33

Inspection, Maintenance and Adjustment

OP000756

4-31

1, 3) Loader arm foot end, 2 locations (1 each side)

(Figure 41).

NOTE: Greased from two remote grease points (1

and 3, Figure 40).

Figure 41

Bucket cylinder head end. Greased from one

remote grease point (Figure 42).

Figure 42

Steering cylinder rod ends, 2 locations (1 each side).

Use remote grease fittings mounted on frame (Figure

43).

Figure 43

Steering cylinder head ends,

2 locations

(1 each

side) (Figure 44).

Figure 44

Inspection, Maintenance and Adjustment

OP000756

4-34

K. Grease rear axle pivot,

2 locations. Use remote

grease fittings mounted on left side of frame (Figure

45).

Figure 45

Grease Upper and Lower Center Pins

Center pins, upper (Figure 46) and lower (Figure 47). Two

locations on right side of machine.

FG001641

Figure 46

FG001642

Figure 47

Replace Engine Oil and Filter

(After First 50 Hours)

NOTE: Replace engine oil and filter after first 50 hours on a

new machine and every 500 hours thereafter.(See

page 4-48)

Inspection, Maintenance and Adjustment

OP000756

4-35

Replace Hydraulic Full Flow Filter

(After First 50 Hours)

NOTE: Replace hydraulic full flow filter after first 50 hours of

operation or rebuild and every

1,000 Hours

thereafter. Follow procedure under

1,000 hour

maintenance interval (See page 4-57).

Check Air Conditioner and Alternator Belt

Tension (After First 50 Hours)

Air conditioner and alternator belt tension must be checked

after first

50 hours of operation to comply with new

machine break-in requirements. After first check, air

conditioner and alternator belt must be checked every 250

hours. Follow procedure printed under

250 hour

maintenance interval

“Check Air-Conditioner and

Alternator Belt Tension” on page 4-39.

Clean Exterior of Radiator, Oil Cooler and

Air Conditioner Condenser

Dust and dirt accumulation on fins of radiator (1), CAC

cooler (4), oil cooler (2), and additional transmission cooler

(3), greatly reduce their cooling efficiency. Use

compressed air, water and steam to clean fins on radiator,

oil cooler, and transmission cooler.

NOTE: On an especially dusty work site, clean fins

every 50 hours. On other work sites, clean fins

every 500 hours.(See page 4-45)

NOTE: You can swing the fan guard for cleaning it‘s fan

blades or radiator easily and efficiently.

NOTE: Before cleaning, please stop the cooling fan by

turning off it‘s engine in order to prevent any

injury from fan rotation.

FG004071

Figure 48

Inspection, Maintenance and Adjustment

OP000756

4-36

Clean Air Conditioner Outer Filter

This unit is equipped with an air-conditioning system. There are

two filters (1 and 2, Figure 49) for air conditioner. They filter out

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

cabin. They are located under the right side control panel.

Open access cover on the lower right side of cabin on the

outside, to gain access filter.

Remove filter (1, Figure 49) and inspect it for damage.

Use compressed air to clean filter. If element is very dirty

use a mild soap and water solution to clean it.

NOTE: Clean air-conditioning filter every 50 hours and

replace a new one every 500 hours of service.

NOTE: If water was used to clean filter be sure it is

completely dry before installation.

NOTE: In the event that the unit it being operated in a

dusty environment, the cleaning and

replacement must be performed more

frequently if filter is damaged, replace damaged

with a new one.

FG003904

Figure 49

WARNING!

All service and inspection of the air-conditioning

system must be performed with the starter switch

in the "O" (OFF) position.

Inspection, Maintenance and Adjustment

OP000756

4-37

250 HOUR / MONTHLY SERVICE

Perform All Daily, 10 Hour and 50 Hour

Service Checks

Check Engine Air Intake Precleaner

The engine is equipped with a precleaner. Dust, insects,

rainwater etc., can be present in the air. The precleaner

collects this material and discharges it. This prevents

material from being drawn into air cleaner. The precleaner

does not need periodic replacement.

Figure 50

Drain Water from Hydraulic Oil Tank

WARNING!

Be certain that hydraulic oil has cooled before draining

water and sediment. Hot oil could splash and cause

burns.

The hydraulic tank is pressurized. Unscrew the cap of

breather on the top of hydraulic tank to allow

pressurized air to vent. After pressure has been

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

service covers.

Position machine on firm, level ground. Lower boom and

position bucket on ground. Shut down engine.

Position a container under hydraulic tank drain plug. Open

tank breather cap (See Figure 20 on page 4-25). Loosen

drain valve at bottom of tank (Figure 51). Allow all water

and sediment to drain out. Tighten drain valve.

NOTE: Dispose of drained fluids according to local

regulations.

Figure 51

Inspection, Maintenance and Adjustment

OP000756

4-38

Turbocharger

The turbocharger is lubricated and cooled by the engine

lubrication system.

Important for the function of the turbocharger is that:

•

lubrication and cooling is safeguarded by

- not racing the engine immediately after it has

been started.

- the engine is allowed to run at low idle for a

couple of minutes before it is turned off.

•

engine oil is changed and oil filters are replaced at

prescribed intervals.

•

the air cleaner is serviced regularly and that the

exhaust system and lubricating oil lines do not leak.

In case jarring noises can be heard, or if the turbocharger

vibrates, it must be reconditioned or replaced immediately.

Only authorized dealer workshops should carry out work on

the turbocharger.

Figure 52

Check Air-Conditioner and Alternator Belt

Adjustable Bolt

Tension

for Air-Conditioner

Loosen the tension adjusting bolts of the alternator, air-

conditioner compressor and air compressor, then take off the

cooling fan.

Adjustable

Link for

Alternator

Belt

Air-Conditioner

Belt

Alternator

Belt

FG013801

Figure 53

Inspection, Maintenance and Adjustment

OP000756

4-39

Grease Drive Shaft

Grease drive shaft center bearing using one grease point.

Figure 54

Replace Transmission Oil and Filter

(After First 250 Hours)

NOTE: Transmission oil and filter must be changed after first

250 hours of operation to comply with new machine

break-in requirements.

NOTE: After first change, oil and filter must be changed

every 1,000 hours. Follow procedure under 1,000

hour maintenance interval. (See page 4-52)

Replace Axle Differential and Planetaries

Oil (After First 250 Hours)

NOTE: The differential and planetaries oil must be drained

and refilled after first 250 hours of operation. There

after every 1,500 hours of operation. (See page 4-59)

Inspection, Maintenance and Adjustment

OP000756

4-40

Clean Outer Filter of Air Cleaner

NOTE: Clean outer filter every 250 hours / monthly service.

NOTE: If air cleaner clogged warning light (Figure 55) on

instrument panel comes "ON" the air cleaner must be

km/h

x100r/min

serviced.

NOTE: When working in severely dusty conditions, the

service interval should be shortened.

FG013171

WARNING!

Figure 55

Never clean or attempt to remove the air cleaner filter if

the engine is running.

This will allow dirt to be sucked into engine and cause

serious engine damage

Always turn engine "OFF" before servicing air cleaner.

Locate the air cleaner assembly.

NOTE: When it reaches every 250 hours or If indicator

light

(Figure

55) on instrument panel comes

"ON" the air cleaner must be serviced.

NOTE: Replace outer filter after cleaning 4 times or

every 1,000 hours / 6 months service.

Remove and clean rubber evacuator valve (1, Figure 57)

from bottom of air cleaner housing cover (2, Figure 57).

Inspect seal lips for wear or damage. Replace valve if

necessary.

Figure 56

NOTE: Install evacuator valve with lips parallel to the

cover.

Remove the access cover (2, Figure 57) by loosening the

latches (3).

Remove the outer filter (4, Figure 57) from the housing. Do

not remove inner filter (5).

FG000702

Figure 57

Inspection, Maintenance and Adjustment

OP000756

4-41

Clean the outer filter (4, Figure 57) by blowing compressed

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

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

WARNING!

If using compressed an to clean the filter, make

sure that proper eye protection is worn.

HAOC570L

Figure 58

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 59

outer and inner filters. Do not clean inner filter.

Water Trap

Take care of fuel spillage by using a vessel or a plastic hose.

Drain the water trap every 250 hours.

Draining water from the fuel has to be done by hand.

A nonreturn valve in the filter head prevents the fuel from

running back to the tank. As no fuel can run back, the pressure

will remain and as a consequence no water will be drained

unless new fuel is pumped in.

FG008506

Figure 60

Proceed as follows:

•

Place the end of the hose in a vessel.

•

Loosen draining nipple (2).

•

Pump with hand pump (3) on the primary filter head

until all water has been forced out of water trap (1).

•

Tighten the draining nipple.

NOTE: Take care of waste oil and liquid in an

open

environmentally safe way!

FG000438

Figure 61

Inspection, Maintenance and Adjustment

OP000756

4-42

500 HOUR / 3 MONTH SERVICE

Perform All Daily, 10, 50 and 250 Hour

Service Checks

Replace Hydraulic System Brake and Pilot

Filter

Replace filter in pilot filter. Perform the following steps:

Vent hydraulic oil tank.

FG008104

Figure 62

Unscrew element cover (5, Figure 63). Cover is filled with

oil. Dispose of oil.

Remove O-ring (3, Figure 63) and filter (4).

Use a nonflammable, nontoxic solvent to clean out cover

(5, Figure 63).

Insert a new filter (4, Figure 63) into cover (5). Install a new

O-ring (3).

Screw cover (5, Figure 63) onto filter head (1).

Figure 63

Inspection, Maintenance and Adjustment

OP000756

4-43

Replace Fuel Prefilter

WARNING!

Exchange filter after waiting for engine to cool. Be

careful of fire hazards. Do not smoke.

Locate fuel filter inside engine compartment.

Position a small container under prefilter. Drain fuel by

opening drain valve on bottom of filter.

NOTE: Dispose of drained fluids according to local

regulations.

Unscrew fuel filter from head assembly. Discard fuel filter.

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

on head until gasket contacts head, turn filter 1/3 - 1/2 turn

more.

FG006241

NOTE: Coat fuel filter gasket with fuel.

Figure 64

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

reduce fuel system priming.

Start engine. After engine has run for a couple of minutes,

shut down engine and look for signs of leaks.

If engine does not start, fuel system may need priming.

Prime fuel system using the following procedure:

A. Loosen plug on top of fuel filter head.

B. Unscrew and pump the hand operated primer pump

near fuel injection pump. Pump primer until fuel is

present at plug hole in fuel filter head.

C. Tighten plug in fuel filter head.

D. Continue to pump primer pump until a strong

resistance is felt. Screw primer pump knob back into

housing.

E. Start engine and look for signs of leaks.

Inspection, Maintenance and Adjustment

OP000756

4-44

Fuel Filter (Spin-On Type)

General Information

Cummins Common Rail Fuel System

The Cummins Common Rail fuel system requires the use of two

fuel filters. The prefuel filter have the following characteristics:

•

water separating

•

30-micron rating

•

hand priming pump

•

chassis mounted.

FG006241

Figure 65

The pressure side main fuel filter must have the following

characteristics:

•

engine mounted

Figure 66

Remove

Disconnect the wiring harness from the fuel heater, if equipped.

Loosen and remove the fuel filter.

Make sure the seal ring does not stick to the filter head.

Remove the ring with an O-ring pick, if necessary.

NOTE: Both fuel filters must be removed at the same time.

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

Screw filter on head until gasket contacts head by hand, turn

filter 3/4 - 1 turn more with filter wrench.

Figure 67

Inspection, Maintenance and Adjustment

OP000756

4-45

Replace Fuel Filter

WARNING!

Exchange filter after waiting for engine to cool. Be

careful of fire hazards. Do not smoke.

Locate fuel filter inside engine compartment.

Position a small container under fuel filter.

Figure 68

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 69

Clean Exterior of Radiator, Oil Cooler and

Air Conditioner Condenser

Dust and dirt accumulation on fins of radiator, oil cooler,

and additional transmission cooler greatly reduce their

cooling efficiency. Use compressed air, water and steam to

clean fins on radiator, oil cooler, and transmission cooler.

NOTE: On an especially dusty work site, clean fins

every 50 hours. On other work sites, clean fins

every 500 hours.

FG013805

Figure 70

Inspection, Maintenance and Adjustment

OP000756

4-46

NOTE: You can swing the fan guard for cleaning it‘s fan

blades or radiator easily and efficiently.

NOTE: Before cleaning, please stop the cooling fan by

turning off it‘s engine in order to prevent any

injury from fan rotation.

Figure 71

Clean Air Conditioner Inner Filter

This unit is equipped with an air-conditioning system. There are

two filters (1 and 2, Figure 72) for air conditioner. The filters out

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

cabin. They are located under the right side control panel.

Open access cover on the lower right side of cabin on the

outside to gain access filter.

Remove filter (2, Figure 72) and inspect it for damage.

Use compressed air to clean filter. If element is very dirty

use a mild soap and water solution to clean it.

NOTE: Clean air-conditioning filter every 500 hours and

replace with a new one every 1,000 hours of

service.

NOTE: If water was used to clean filter be sure it is

completely dry before installation.

NOTE: In the event that the unit it being operated in a

dusty environment, the cleaning and

replacement must be performed more

frequently if filter is damaged, replace damaged

with a new one.

FG003904

Figure 72

WARNING!

All service and inspection of the air-conditioning

system must be performed with the starter switch

in the "O" (OFF) position.

Inspection, Maintenance and Adjustment

OP000756

4-47

Replace Engine Oil and Filter

CAUTION!

Never attempt to change oil or filter on a hot engine.

Hot oil could splash and cause burns. Allow engine to

cool down before changing oil or filter.

NOTE: Change engine oil and filter after first 50 hours on a

new machine and every 500 hours thereafter.

Position a larger container under drain valve beside left

wall of fuel tank. Loosen drain valve and allow all engine oil

to drain out. Tighten drain valve.

NOTE: Oil warming is good when replacing oil. If

machine is cold, operate the engine to bring the

coolant temperature up to about 40°C (104°F).

When the needle of the coolant temperature

gauge reaches the middle of the "WHITE

ZONE," the temperature is about 40°C (104°F).

NOTE: Dispose of drained fluids according to local

regulations.

Figure 73

Replace engine oil filter (Figure 74). Engine oil filter is a

spin-on type. Remove and discard filter.

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

gasket. Screw filter on head until gasket contacts head by

hand, turn filter 3/4 - 1 turn more with filter wrench.

NOTE: See

“Fluid Capacities” on page 4-16, for

capacity and

“Table of Recommended

Lubricants” on page 4-14, of this manual for

recommended oil for the operating conditions.

Fill engine with correct oil through oil fill port.

Figure 74

Start engine and check engine oil pressure warning light.

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

oil level.

CAUTION!

The lubricating oil filter must be full of oil at start-up to

prevent engine damage.

Use clean 15W-40 oil to coat the gasket surface of the filter.

Fill the filter with clean 15W-40 oil.

Figure 75

Inspection, Maintenance and Adjustment

OP000756

4-48

1,000 HOUR / 6 MONTH SERVICE

Perform All Daily, 10, 50, 250 and 500 Hour

Service Checks

Air Cleaner

CAUTION!

Never remove air cleaner filter while engine is running.

This will allow dirt to be sucked into engine and cause

serious engine damage. Always turn engine "OFF"

before servicing air cleaner.

Engine, Air Cleaner

The degree of engine wear depends largely on the cleanliness

of the induction air. The air cleaner prevents dust and other

impurities from entering the engine. Therefore, it is very

important that the air cleaner must be checked regularly and

maintained correctly.

Primary Filter, Maintenance and Replacement

When the alarm text "Clogged Air Filter" is shown or every 1,000

hours, the filter must be replaced or be cleaned. The period of

operation between filter replacements vary depending on the

working environment of the machine. In certain environments

the filter needs to be replaced more often.

•

The filter can be cleaned according to instructions

which your authorized dealer will give you. However,

after the filter has been cleaned five times or if it is

damaged, it must be replaced.

NOTE: Make a mark on the decal at the end of the

Figure 76

secondary filter every time the primary

filter is replaced or cleaned.

•

In connection with replacing the filter, the cover for

the air cleaner should also be cleaned. It works as a

container for particles which have not been trapped in

the filter.

•

Check that all hose and pipe connections from the air

cleaner to the engine induction manifold are tight.

Check tightness of hose clamps.

•

If the alarm text remains after replacing the primary

filter, also the secondary filter must be replaced. See

“18. Air Cleaner Clogged Warning Light” on

page 2-19

Inspection, Maintenance and Adjustment

OP000756

4-50

Do not, under any circumstances, run the engine without a filter

or with a damaged one.

Always have a spare filter on hand and keep the filter well

protected from dirt.

CAUTION!

Never clean the inside of air filter housing while the

inner filter is not installed.

Secondary Filter

Replace the filter every 2,000 hours or when the main filter has

been replaced three times.

The filter cannot be cleaned, but must be replaced.

The secondary filter works as a protective filter if the main filter is

damaged.

Never remove the secondary filter unless it is to be replaced.

Figure 77

Replace Outer Air Cleaner Element

CAUTION!

Never remove air cleaner element while engine is

running. This will allow dirt to be sucked into engine

and cause serious engine damage. Always turn engine

"OFF" before servicing air cleaner.

Open the side access cover at the rear of the cabin.

Remove the evacuator valve (1, Figure 78) and air cleaner

FG000425

cover (2, Figure 78).

Figure 78

NOTE: Inspect evacuator valve seal lips for wear or

damage. Replace valve if necessary. Install

evacuator valve with lips parallel to the cover.

Inspection, Maintenance and Adjustment

OP000756

4-51

Remove outer filter (4, Figure 78) from the air cleaner

housing.

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

housing. Do not use compressed air to blow out housing.

Install new outer filter.

Install air cleaner cover and evacuator valve.

NOTE: Make sure that all gaskets on wing nuts and

cover are properly installed and seated.

Drain and Replace Transmission Oil and

Filter

NOTE: Transmission oil and filter must be changed after first

250 hours of operation to comply with new machine

break-in requirements. After first change, oil and filter

must be changed every 1,000 hours.

Use two people to perform this operation.

Start machine and drive it until transmission fluid has

warmed to 80°C (176°F). Park machine on firm, level

ground. Lower bucket to ground.

Place transmission lever in "NEUTRAL." Apply parking

brake. Shut down engine. Block tires.

NOTE: See

“Fluid Capacities” on page 4-16, for

capacity and

“Table of Recommended

Lubricants” on page 4-14, of this manual for

recommended oil for the operating conditions.

Remove drain plug. Allow all transmission fluid to drain into

a receptacle. Clean drain plug (Figure 79).

NOTE: Dispose of drained fluids according to local

regulations.

Install drain plug in transmission.

Remove inlet strainer. Use a nonflammable, nontoxic

solvent to clean strainer.

Inspect gasket on inlet strainer. Replace gasket if it is

damaged. Install inlet strainer.

FG004072

Remove breather filter. Clean breather filter and install it.

Figure 79

Inspection, Maintenance and Adjustment

OP000756

4-52

Rotate filter counterclockwise to remove it (Figure 80).

10. Clean filter head.

11. Grease filter gasket and gasket mating surface on filter

head.

12. Thread filter onto filter head. Tighten filter 1/2 turn after

filter gasket contacts filter head. Filter must be torque to

1.6 - 2.1 kg•m (11.5 - 15 ft lb).

FG002218

Figure 80

13. Fill transmission with fluid through transmission fill tube

(Figure 81).

FG013811

Figure 81

14. Add fluid until fluid level reaches low mark on dipstick

(Figure 81).

15. Start engine. Idle engine for two minutes. Have a person

remain in the cabin.

16. With engine idling, have second person check

transmission fluid level again. Add fluid until level reaches

high mark on dipstick.

17. Idle engine until transmission fluid temperature reaches

80°C (176°F). Check fluid level with engine idling. Level

must reach high mark on dipstick.

HAOC280L

Figure 82

NOTE: If oil level is above top high mark on dipstick,

drain oil until level is at high mark.

NOTE: If transmission cannot reach an operating

temperature of 80°C (176°F), then the oil level

must be below the high mark. Periodically check

oil level during the workday to ensure that oil

level does not rise above high mark on dipstick.

18. Check filter for leaks while engine is running.

Inspection, Maintenance and Adjustment

OP000756

4-53

Clean Fuel Tank and Strainer

WARNING!

Fuel is flammable and harmful to skin.

•

Do not smoke while draining moisture and

sediment from fuel tank.

•

Do not drain fuel with engine running.

•

Do not allow fuel to remain on skin for an

extended period of time. Wash thoroughly with

soap and water.

NOTE: It is easier to clean the fuel tank when it is almost

empty.

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground, and shut down

engine.

Drain fuel tank.

Remove cover and strainer located on bottom of tank.

Use a nonflammable, nontoxic, parts cleaner to clean

strainer and any sediment inside tank.

Install strainer and cover.

Figure 83

Figure 84

Inspection, Maintenance and Adjustment

OP000756

4-54

Replace Air Conditioner Inner Filter

NOTE: This 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 must be

cleaned out every 500 hours and replaced with a new

one every 1,000 hours. For filter replacement See

“Clean Air Conditioner Inner Filter” on page 4-47

NOTE: In the event that the equipment is being operated in a

dusty environment, the cleaning and replacement

must be performed more frequently.

Check Air Conditioner Refrigerant

WARNING!

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging

air-conditioning system.

Apply the parking brake and lower attachment to the

ground.

Remove the cover.

Figure 85

Press the "HI" flow control switch to set maximum air flow.

Set the temperature control switch fully to the cool position

and fully open the cabin doors.

Slightly accelerate the engine to about the middle speed

range (compressor speed 1500 - 1800 rpm).

Compare the flow of bubbles in the sight glass 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.

Figure 86

Inspection, Maintenance and Adjustment

OP000756

4-55

Amount of

Appearance of the Sight Glass

Solutions

Refrigerant

Almost clear.

Normal

Any bubbles disappear if the engine

speed is increased to 1500 rpm.

High

No bubbles are seen.

Contact your local DOOSAN

loader dealer for inspection and

recharging refrigerant.

Low

A flow of bubbles is visible.

Check and Adjust Engine

Contact your nearest DOOSAN loader dealer.

Contact engine manufacturer for checking and adjusting the

following items:

•

Engine Compression Pressure.

•

Injection Pressure.

•

Injection Timing.

Inspection, Maintenance and Adjustment

OP000756

4-56

Replace Hydraulic Full Flow Filter

WARNING!

The hydraulic oil will be hot after normal machine

operation. Allow system to cool before attempting to

service any of the hydraulic components.

The hydraulic tank is pressurized. Loosen hydraulic oil

fill cap slightly to allow pressurized air to vent. After

pressure has been released, it is safe to remove either

the fill cap or service covers or drain water from the

tank.

IMPORTANT

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

hydraulic tank, especially around fill port and filter

ports.

NOTE: Replace hydraulic full flow filter after first 50 hours of

operation or rebuild and every 1000 Hours thereafter.

Remove access cover (Figure 87) from front frame.

Figure 87

Loosen breather cap on hydraulic oil tank.

Clean filter cover (Figure 88) and area around cover on

hydraulic oil tank.

Figure 88

Inspection, Maintenance and Adjustment

OP000756

4-57

Remove bolts (1, Figure 89) from cover (2).

Lift cover (2, Figure 89) and O-ring (4) off hydraulic oil tank.

Control spring (3) sits beneath cover. Remove spring (3).

Remove valve (5, Figure 89) and filter element (6) from

hydraulic oil tank.

Clean underside of cover (2, Figure 89).

Set a new filter element (6, Figure 89) and valve (5) down

into hydraulic oil tank. Press element down onto its base

until top of element is approximately 4 mm (0.157") below

edge of hydraulic oil tank.

Install a new O-ring (4, Figure 89) on cover (2). Set spring

(3) into place on element (6).

10. Set cover (2, Figure 89) into place over element (6). Install

bolts (1) through cover (2) and tighten them.

HBOM402L

Figure 89

11. Tighten breather cap on hydraulic oil tank.

Inspection, Maintenance and Adjustment

OP000756

4-58

1,500 HOUR / 9 MONTH SERVICE

Perform All Daily, 10, 50, 250 and 500 Hour

Service Checks

Replace Axle Differential and Planetaries

Oil

NOTE: Oil in both front and rear axles must be replaced after

first

500 hours of operation to comply with new

machine break-in requirements. After that, axle oil

check must be done every 500 hours of operation

and replacement must be done every 1,500 hours.

Each axle contains a center differential, and a planetary on each

end. The same oil lubricates the center differential and

planetaries. These sections of the axle are connected, but the oil

flows very slowly between them. When checked, oil must be

checked and refilled at the level/fill plug on the differential

housing.

To drain and replace oil in an axle, perform the following steps:

Drive machine onto a level surface. Position wheels on

axle being drained so that axle end level plugs (1, Figure

90) are in the lowest position. Apply parking brake. Block

wheels.

Clean areas around drain plugs on both ends of axle.

Remove plugs.

NOTE: See

“Fluid Capacities” on page 4-16 for

capacity and

“Table of Recommended

Lubricants” on page 4-14 of this manual for

recommended oil for the operating conditions.

NOTE: Dispose of drained fluids according to local

Figure 90

regulations.

Clean area around level plug (1, Figure 91) and drain plug

(2) on center differential. Remove level plug and drain

plug. Allow oil to drain into a suitable container.

Install drain plug Figure

91into center differential, and

tighten.

Pump oil into level plug hole on center differential. Add oil

until oil level is even with bottom of plug hole.

Figure 91

Inspection, Maintenance and Adjustment

OP000756

4-59

Go to level plug holes (1, Figure 92) on axle ends. Add oil

to these openings until oil level is even with bottom of plug

hole. Recheck level on center differential. Add oil if

necessary. When oil level is satisfactory at all three level

plug holes, install and tighten level plugs at all three

locations.

Repeat procedure for other axle.

FG002222

Figure 92

Axle Brake Disk Wear Measurement

NOTE: A wear measurement on the multidisk brake

must be made at least once a year, especially in

case of a change in braking behavior like, e.g.

•

Braking noise.

•

Braking power reduced.

•

Deceleration changed.

•

Brake fluid level changed.

•

Braking pressure changed.

Insert feeler gauge into oil level check hole to check

thickness of brake disks.

NOTE: Minimum thickness: s = 4.5mm (0.18 in)

Figure 93

Inspection, Maintenance and Adjustment

OP000756

4-60

2,000 HOUR / YEARLY SERVICE

Perform All Daily, 10, 50, 250, 500 and

1,000 Hour Service Checks

Replace Inner Air Cleaner Element

CAUTION!

Never remove air cleaner element while engine is

running. This will allow dirt to be sucked into engine

and cause serious engine damage. Always turn engine

"OFF" before servicing air cleaner.

NOTE: Replace outer element after cleaning 4 times or every

1,000 hours.

Replace inner filter when outer filter is replaced.

After removing outer filter, remove wing nut and inner filter.

Clean out inside of air cleaner housing. Do not use

compressed air to blow out housing.

Install new inner filter, and secure it into position with wing

nut. Do not clean and reuse inner filter.

Install new outer filter, and secure it into position with wing

nut.

Install air cleaner cover.

NOTE: Make sure that all gaskets on wing nuts and

cover are properly installed and seated.

Check Steering, Brake, Drive Shaft,

Engine, and Fuel System

Inspection, Maintenance and Adjustment

OP000756

4-61

Replace Pipes and Hoses

Replace hoses that carry brake fluid to wheel brakes. Also

replace hoses that carry hydraulic fluid to steering

cylinders.

It is difficult to determine condition of many hoses. The

best way to ensure safe operation and to maintain

maximum performance is to replace hoses on a regular

basis. If any brake or steering hoses become damaged or

appear defective in any way, replace them immediately

despite time interval since their last replacement.

Bleed Brakes

When brake hoses or brake tubes are replaced, air can be

introduced into brake hydraulic system. Air can cause brakes to

operate intermittently, which is a dangerous condition. Never

operate machine with air in brake hydraulic system. A spongy

feel when pressing brake pedal is a sign that air is present in

brake hydraulic system.

To bleed air out of brake hydraulic system, perform the following

steps: (Figure 94)

Start engine and place transmission in "NEUTRAL."

Remove rubber cap from bleeder screw on wheel.

Place one end of a plastic hose (2) over bleeder screw (1).

Place other end of hose in a container (3) filled with brake

fluid.

Station one person in operator’s cab, and one person at

bleeder screw on wheel being bled.

Open bleeder screw (1). Then press down on brake pedal

until it rests on floor of cab. Hold pedal down on floor of

HLB3018L

cab. Close bleeder screw while pedal is being held down.

Figure 94

After bleeder screw has been closed, allow brake pedal to

return to upright position. Continue to open bleeder screw

and press down pedal as described in this step, until fluid

expelled from bleeder hose has no air bubbles present.

Securely close bleeder screw (1). Install rubber cap on

bleeder screw.

Inspection, Maintenance and Adjustment

OP000756

4-62

Replace Radiator Coolant

NOTE: Do not mix ethylene glycol and propylene glycol

antifreeze together. If the two are mixed, the

protection level will be reduced to the level of the

ethylene glycol. See

“Engine Cooling System” on

page 4-72, for further details.

NOTE: This unit was factory filled with propylene glycol.

WARNING!

Allow the engine to cool before releasing the radiator

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

remaining pressure.

Radiator cleaning is performed while the engine is

running. Take extreme caution when working on or near

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

controls notifying personnel that service work is being

FG013813

performed.

Figure

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

Slowly open the radiator cap (Figure 95) to allow any

pressure to escape.

NOTE: See

“Fluid Capacities” on page 4-16 for

capacity.

Place a container under the radiator and open the drain

valve (Figure 96).

NOTE: Dispose of drained fluids according to local

regulations.

Figure 96

Inspection, Maintenance and Adjustment

OP000756

4-63

Replace Hydraulic Oil and Clean Oil

Suction Strainer

CAUTION!

Be certain that hydraulic oil has cooled before draining

it. Hot oil could splash and cause burns.

Raise boom to its highest position. Tilt bucket back as far

as possible, and shut down engine.

NOTE: See

“Fluid Capacities” on page 4-16 for

capacity.

Figure 97

Position a catch tank beneath hydraulic oil tank drain plug.

Open hydraulic oil tank breather cap. (See Figure 18 on

page 4-24). Remove drain plug from bottom of hydraulic oil

tank. (Figure 98). Allow all hydraulic oil to drain out.

NOTE: See See “Fluid Capacities” on page 4-16 for

capacity.

Figure 98

Figure 99

Inspection, Maintenance and Adjustment

OP000756

4-64

Figure 100

Without starting engine, operate controls to dump bucket.

(Figure 99). Then operate controls to lower boom. (Figure

100). This will drain oil out of boom and bucket cylinders.

Replace full flow hydraulic filters as described under

“Replace Hydraulic Full Flow Filter” on page 4-57.

Remove and clean pump inlet strainer (7, Figure 101) that

is located inside hydraulic oil tank.

A. Disconnect hose (1, Figure 101) from strainer cover

(2).

Figure 101

B. Remove bolts (1, Figure

102) that retain strainer

cover (2).

C. Remove strainer cover (2, Figure 102) and strainer

(3) from hydraulic oil tank.

D. Remove strainer (3, Figure 102) from strainer cover

(2).

E. Clean strainer (3, Figure 102) in a nonflammable,

nontoxic solvent.

F. Mount strainer (3, Figure 102) on strainer cover (2).

G. Insert strainer

(3, Figure

102) and cover (2) into

Figure 102

hydraulic oil tank.

NOTE: Make sure that O-ring for cover is not damaged

and properly seated.

H. Install and tighten bolts (1, Figure 102) that retain

cover (2).

Inspection, Maintenance and Adjustment

OP000756

4-65

Install hydraulic oil tank drain plug. Refill tank by pouring oil

in through breather cap opening. Install and tighten

breather cap.

Start engine and operate controls to raise and lower bucket

a few times. (Figure 103). Raise and lower boom a few

times. (Figure 104). Lower bucket to ground.

Check hydraulic oil tank sight gauge (Figure 17). Oil level

must be between upper limit and lower limit on sight

gauge. Remove breather cap and add oil if necessary.

Figure 103

Figure 104

Check Brake Accumulator

WARNING!

Pressurized Nitrogen gas in brake accumulator may

explode causing serious injury or death.

Never service brake accumulator unless properly trained.

Test the brake accumulator for proper precharge of Nitrogen

gas:

Park the machine on a level surface, apply the parking

brake, lower the attachment to the ground.

Run the engine at low idle for five minutes to fill the brake

accumulator with oil.

Shut down engine.

Turn the starter switch to "ON" position.

Count the number of times you can depress the right-hand

brake pedal before the brake warning light comes on.

If the number counted is less than five (5), there is some

problem with the accumulator. Contact your nearest

DOOSAN dealer.

Inspection, Maintenance and Adjustment

OP000756

4-66

12,000 HOUR / SIX YEAR

SERVICE

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)

European regulations state that the in-service life of any

hydraulic hose may not exceed six years. DOOSAN

recommends the following:

•

Hoses at the customer premises cannot be stored

more than 2 years before being discarded or installed

on a machine.

•

In-service lifetime of hoses fitted on a machine can

never exceed 6 years, but replace hoses described in

“Replace Pipes and Hoses” on page 4-62, every

year. 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

OP000756

4-67

SEVERE CONDITIONS

MAINTENANCE

Operating Condition

Required Maintenance

Mud, Water, Rain

Check for loose fittings, obvious damage to machine, or

any fluid leakage.

After completing operations, clean mud, rocks, or debris

from machine. Inspect for damage, cracked welds, or

loosened parts.

Perform all daily lubrication and service.

If machine was working in salt water or other corrosive

materials, be sure to flush equipment with fresh water.

Extremely Dusty

Hot

Clean engine air filter on a more frequent basis.

Environment

Clean radiator and oil cooler fins to remove dirt and dust.

Clean fuel system intake strainer and fuel filter more

frequently.

Inspect starter motor and alternator, and clean as often as

necessary.

Rocky Terrain

Check wheels, tires, rims, and valve stems for damage or

excessive wear.

Inspect for loose or damaged fittings and bolts.

On a more frequent basis, inspect bucket and boom for

damage or excessive wear.

Install a top guard and front guard as necessary for

protection against falling rock.

Extreme Cold

Use proper grade of fuel for cold temperatures.

Use a gauge to check antifreeze to be sure that it will

provide protection for coldest temperature expected.

Use a hydrometer to check condition of batteries. In

extremely cold weather, remove batteries at night and

store them in a warm area.

Inspection, Maintenance and Adjustment

OP000756

4-68

BOLT TORQUE CHART

Tightening Torque Specifications for

Metric Bolts (For coated threads,

prelubricated assemblies)

Grade

Gr. 8.8

Gr. 10.9

Gr. 12.9

Dia.

kg•m

ft lb

kg•m

ft lb

kg•m

ft lb

5 mm x std.

0.59

4.3

0.79

5.7

1.0

7.2

6 mm x std.

1.00

7.3

1.38

1.66

8 mm x std.

2.49

3.46

4.15

8 mm x 1.0

2.76

3.87

4.56

10 mm x std.

4.84

6.92

8.30

10 mm x 1.0

4.84

7.05

8.30

12 mm x std.

8.57

11.89

14.52

105

12 mm x 1.5

9.00

12.59

14.94

108

14 mm x std.

13.55

18.95

137

23.10

167

14 mm x 1.5

14.94

108

21.02

152

24.89

180

16 mm x std.

20.88

151

29.46

213

35.54

257

16 mm x 1.5

22.54

163

31.53

228

38.03

275

18 mm x std.

28.90

209

40.52

293

48.41

350

18 mm x 1.5

32.50

235

45.92

332

55.04

398

20 mm x std.

40.94

296

57.95

419

69.01

499

20 mm x 1.5

46.05

333

64.03

463

77.03

557

22 mm x std.

54.90

397

77.86

563

93.08

673

22 mm x 1.5

61.00

441

86.02

622

105.00

759

24 mm x std.

71.00

513

100.00

723

120.00

868

24 mm x 2.0

78.00

564

109.95

795

130.00

940

27 mm x 2.0

115.06

832

160.00

1157

195.00

1410

Inspection, Maintenance and Adjustment

OP000756

4-69

ELECTRICAL SYSTEM

Check Battery Condition

WARNING!

Before starting any battery service work, make sure to

shut the engine off and turn the starter switch to the "I"

(OFF) position.

The batteries create hydrogen gas. An explosion hazard

exists, particularly with a deeply discharged battery.

Make sure that open flames, burning objects or sparks

are kept away from the battery compartment.

Battery electrolyte is diluted sulfuric acid. Take extreme

caution when handling the batteries. The electrolyte can

cause severe chemical burns. If any electrolyte gets on

your clothing or skin, wash it off immediately with large

quantities of water. If the electrolyte gets into your eyes,

flush them immediately with a large quantity of water

and contact a doctor at once.

When installing a battery, wear safety glasses at all

times.

When removing a battery, remove the negative

(-) or

ground terminal first, and then the positive (+) terminal.

This will prevent sparks or arcing that could cause an

explosion. When installing a battery, connect the

positive terminal first and then the negative terminal.

Make sure to fully tighten the terminal clamps.

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 of battery electrolyte level.

NOTE: The battery installed at the factory is a

Maintenance Free (MF) type. Electrolyte under

normal conditions should remain at its proper

level.

HJB5002L

Figure 105

Inspection, Maintenance and Adjustment

OP000756

4-70

Inspect charge condition of battery by looking at the

indicator light built into battery.

•

GREEN: Normal.

•

BLACK: Insufficient charging - check alternator.

•

TRANSPARENT: Insufficient battery electrolyte

replace with new battery.

NOTE: Colors may vary from one battery manufacturer

to another. Always refer to instructions on

battery.

The batteries should always be replaced in

pairs. Using an old battery with a new one will

shorten the life span of the new battery.

Inspection, Maintenance and Adjustment

OP000756

4-71

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 2.1 kg/cm² (30

psi). 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

OP000756

4-72

Types of Antifreeze

There are two main classifications of antifreeze available on the

market today.

Ethylene Glycol - Standard Life Antifreeze

Propylene Glycol - Extended Life Antifreeze

Ethylene glycol (standard life antifreeze) has been on the market

for many years. Its chemical properties do not provide the

improved corrosion resistance that propylene glycol (extended

life antifreeze) does. Ethylene glycol is also very hazardous to

the environment, people and animals. DOOSAN recommends

that ethylene glycol be replaced with propylene glycol.

The newer propylene glycol antifreeze comes in many different

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

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

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

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

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

Keep careful machine records of what brand and type of

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

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

NOTE: Do not mix ethylene glycol and propylene glycol

antifreeze together. If the two are mixed, the

protection level will be reduced to the level of the

ethylene glycol.

Antifreeze Concentration Tables

Ethylene Glycol - Standard Life Antifreeze

(1,000 Hour / 6 Months)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-4°F)

67%

33%

-25°C (-13°F)

60%

40%

-30°C (-22°F)

56%

44%

-40°C (-40°F)

50%

Propylene Glycol - Extended Life Antifreeze

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

78%

22%

-15°C (5°F)

71%

29%

-20°C (-4°F)

65%

35%

-25°C (-13°F)

59%

41%

-30°C (-22°F)

55%

45%

-40°C (-40°F)

48%

52%

Inspection, Maintenance and Adjustment

OP000756

4-73

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 "I" (ON) position and

operate pilot control valve lever and brake pedal. Even

though the engine is shut down, hydraulic actuated

components may move while releasing pilot pressure.

Keep all personnel away from machine while performing

this operation.

•

Set pilot cutoff switch to "O"

(OFF) 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:

Lower front attachment (bucket) to ground.

Shut down engine.

Set pilot cutoff switch on "I" (ON) position.

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

Fully move pilot control valve lever in all directions.

Repeatedly press brake until brake oil pressure warning

FG008106

light turns "ON." Press the pedal another eight to nine

Figure 106

times.

Set pilot cutoff switch on "O" (OFF) position.

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

switch.

Remove accumulator by unscrewing it slowly.

Inspection, Maintenance and Adjustment

OP000756

4-74

HYDRAULIC PRESSURE

CHECKS

Hydraulic pressures for most systems can be check by using the

remote test ports shown in Figure 107.

Port Number

Description

Specification

Steering Pump Pressure

175 ± 5 Bar

Main Pump Pressure

200 ± 5 Bar

Transmission System

16 ~ 18 Bar

Pressure

Brake Charge Pressure

120 ~ 140 Bar

Figure 107

Main Pump Pressure

Remove access cover (Figure 108) from front frame.

Attach gauge to (Port 1, Figure 107).

Relief cartridge for main pump must open at 195 - 205 kg/

cm² (2770 - 2900 psi).

Figure 108

To adjust pressure, use screw on relief valve cartridge

(Figure 109), loosen lock nut and turn screw clockwise to

raise relief pressure. Turn screw counterclockwise to lower

relief pressure.

Tighten lock nut after pressure has been adjusted.

Figure 109

Inspection, Maintenance and Adjustment

OP000756

4-75

Brake Charge Pressure

Attach gauge to (Port 2, Figure 107).

Figure 110

Loosen lock nut on adjusting screw of unloader valve

cartridge (Figure 111). Turn adjusting screw clockwise to

raise relief pressure. Turn adjusting screw counterclockwise

to lower relief pressure.

Relief pressure should be set at 120 kg/cm² (1,710 psi)

cut-in and 140 kg/cm² (1,990 psi) cut-out.

Tighten lock nut after adjustment has been made.

Figure 111

Transmission Clutch Pressure

Attach gauge to (Port 3, Figure 107).

It is not impossible to adjust pressure.

Transmission Pressure

16 - 18 kg/cm² (228 - 256 psi)

Figure 112

Inspection, Maintenance and Adjustment

OP000756

4-76

Steering Pump Pressure

Attach gauge to (Port 4, Figure 107).

Adjust relief valve cartridge on steering valve (Figure 113).

Cartridge must be adjusted to open at 170 - 175 kg/cm²

(2420 - 2490 psi).

Figure 113

Remove plug and washer (Figure 114). Adjust screw that

is located beneath plug. Turn screw clockwise to raise

relief pressure. Turn screw counterclockwise to lower relief

pressure.

Install plug and washer after pressure has been adjusted.

Figure 114

Pilot Control Valve Lever (Joystick)

Activation Pressure

Figure 115

Loosen lock nut on adjusting screw of pilot relief cartridge

(Figure 116). Turn adjusting screw clockwise to raise relief

pressure. Turn adjusting screw counterclockwise to lower

relief pressure.

Relief pressure should be set at 37.0 ±3 kg/cm² (526 ±43

psi).

Tighten lock nut after adjustment has been made.

Figure 116

Inspection, Maintenance and Adjustment

OP000756

4-77

Fan Motor Pressure and Fan rpm

The motor intergrates a proportional pressure relief valve, the

fan speed (and thus the cooling performance) can be infinitely

controlled depending on two different simultaneous input signals

from temperature sensors.

The cooling fan controller processes the two input signals and

controls the valve coil current. The proportional relief valve has a

fail safe characteristic, this means, max. relief valve setting is

adjusted automatically if the voltage supply is interrupted (e.g.

broken wire). This results in a max. fan speed and therefore in a

max. cooling performance.

Standard

Fan Motor Pressure

160 ± 5 bar (Speed Control)

136 ± 5 bar (Without Speed Control)

500 ~ 1,800 (Speed Control)

Fan rpm

1,800 (Without Speed Control)

FG001746

Figure 118

Reference

Description

Number

Engine

Cooling Fan

Cooling Pump

Temperature Sensor (T/M Oil)

Cooler

Temperature Sensor

(Coolant Water)

Cooling Fan Controller

Transmission

Fan Motor

Inspection, Maintenance and Adjustment

OP000756

4-79

Checking the Relief Pressure of Fan Motor

FG013090

Figure 119

Reference

Description

Number

Fan Motor

Outlet Line

Fan Guard

Relief Valve

Inlet Line

Maximum Fan Speed, Checking

Open the radiator grille in order to connect the pressure

gauge.

Connect the pressure gauge to the pressure port (6) on the

inlet hose

(3). Check the maximum pressure by fully

depressing the accelerator pedal and reading the pressure

gauge. Maximum fan motor pressure: 160 ±2 kg/cm² (The

fan speed is approximately 1800 rpm at this time)

Inspection, Maintenance and Adjustment

OP000756

4-80

LONG TERM STORAGE

Cleaning

Pressure wash machine. Inspect machine for any damage or

missing parts. Drive machine to check steering linkage for

damage.

Hydraulic System

Start engine and allow it to idle for a few minutes. Drive machine

around for two - three minutes. Raise and lower boom two -

three times. Crowd and dump bucket two - three times. This will

circulate hydraulic fluid through all hydraulic systems.

Lubrication

Perform all daily maintenance procedures listed in this section

(Section 4.) Grease all grease fittings in steering linkage. Apply

a coating of light oil to all exposed cylinder rods. Apply a coating

of light oil to all control linkages and all control valve spools.

Check condition of oil coating each month and add to coating

where necessary.

Battery

Disconnect cables from battery, or remove battery from

machine. If battery is removed, fully charge battery and store it.

Cooling System Care

If cooling system does not need antifreeze and is filled with

water only, add an anti-rust additive. If temperatures below

freezing are expected, add antifreeze to protect system to level

of cold expected. See antifreeze protection Table 4-1. Use a

hydrometer to check level of antifreeze protection once each

month. If desired, cooling system can be completely drained. If

system is drained, place a sign in operator's cabin to warn

operator that there is no coolant in engine.

Inspection, Maintenance and Adjustment

OP000756

4-81

PARKING BRAKE ADJUSTMENT

To adjust parking brake, perform the following steps:

Jack up machine enough to allow tires to rotate freely.

Turn “OFF” engine and place transmission lever in “NEUTRAL.”

Turn ignition switch to “ON” position. Move parking brake switch

to “UNLOCKED” position.

Front Axle Service Brakes

Checking clearance between brake pad and brake disc in the

front axle.

Locate the pinion adjusting bolt in the upper part of the

differential housing.

Remove lock bolt (2, Figure 120) and bracket (1).

Rotate the square pinion adjusting bolt (3, Figure 120) in

counter clockwise direction until it stops. At this time the

clearance of brake disk is “0”.

Rotate adjusting bolt (3, Figure 120) clockwise four turns (0.25

mm / rotation) to set the clearance to 1 mm (0.4 in).

Install lock bracket (1, Figure 120) and bolt (2).

Repeat steps 1-5 for other side.

Front Axle Parking Brake Emergency

Release

Locate parking brake release bolt on the lower section on

both sides of the housing.

Loosen lock nut (4, Figure 120) from adjusting bolt (5).

Tighten adjusting bolt (5, Figure 120) until it stops. This will

manually release the parking brake so that the drive shaft

will be free to turn.

The initial setting of adjusting bolt is 47 mm and should be

readjusted to this length and lock nut tightened after towing is

complete.

Figure 120

Rear Axle Service Brake

There are three adjusting bolts per side at 120° intervals for the

rear axle brake adjustment. All three must be adjusted for proper

operation. The adjusting procedure is same as the front brake

adjustment method and must be repeated for both sides.

Inspection, Maintenance and Adjustment

OP000756

4-82

TIRES

Inflating Tires

Recommended tire pressures should normally be followed.

Special operations may justify a different pressure. In such

cases, follow the instructions from the tire manufacturer and do

not exceed the maximum permissible pressures, (See page

4-85)

The tire pressure may have been raised before the machine was

delivered from the factory. Therefore, check and adjust the tire

pressure according to recommendations, before putting the

machine to work for the first time.

WARNING!

Repair work on tires and rims must be carried out by

persons who have been especially trained for this.

The instructions stated below apply to an inflated tire

where the pressure needs to be increased. If the tire

has lost all pressure, a trained service engineer must be

called in.

•

When checking the air pressure, the tire must be cold

and the machine not have a load.

•

Ask all other persons to leave the danger area (in

front of the rim).

•

Stand by the tire tread as shown in the figure. Tire

installed on a split rim may explode causing injury or

in the worst case death.

•

Use a long air hose (with a self attaching air chuck)

which allows you to stand outside the danger area.

•

Tires on stored wheels (spare wheels) must be kept

laying down on their side, and only be inflated

sufficiently to keep the rim parts in position.

Wheel Nut, Tightening Check

After having changed a tire or if the wheel has been removed

and installed for any other reason, the wheel bolts must be

check for tightness after eight hours of operation.

Tighten wheel nuts to 85 kg•m (615 ft lb).

Inspection, Maintenance and Adjustment

OP000756

4-83

Wheel Nut Torque

Tighten wheel nuts to58 - 62 kg•m (420 - 448 ft lb).

WARNING!

If a wheel and tire must be removed from machine and

replaced, or if a tire must be replaced on wheel, allow

this task to be performed only by experienced service

personnel. A tire rim could be propelled off wheel and

cause serious bodily injury or death. See Figure 121.

Figure 121

Check Tire for Damage

WARNING!

Improper servicing or changing tires and rims can cause

explosion resulting in serious injury or death.

Do not service or change tires and rims unless properly

trained and equipped.

Contact your nearest DOOSAN loader dealer or tire

manufacturer's local dealer for tire servicing or

changing.

WARNING!

An overheated tire may explode causing serious injury

or death.

If overheated tire is suspected, do not approach tire to

distance of less than 15 m (50 ft).

Stay away until tire and rim cool down.

If the following defects are found in tires, for safety reasons the

tires must be replaced with new tires.

For the replacement contact DOOSAN loader dealer or a tire

manufacturer's local dealer.

•

Bead wire is broken or bent, or the tire is greatly

deformed.

•

Wear is excessive and the carcass ply (including

breaker) is exposed for more than

1/4 of the

circumference.

•

Damage to the carcass exceeds 1/3 of the tire width.

Figure 122

Inspection, Maintenance and Adjustment

OP000756

4-84

•

Tire layers are separated.

•

Radial cracks reach the carcass.

•

Deformation or damage which makes the tire

unsuitable for use.

Recommended Air Pressure

Working Pressure

Driving Pressure

Tires

Remarks

Front

Rear

Front

Rear

+0.1

3.5

Bar

3.0

Bar

3.5

Bar

3.0

Bar

17.5R25(L2)

Radial Ply Tire

(Standard)

(50

psi)

(43.5

psi)

(50

psi)

(43.5

psi)

+0.1

4.2

Bar

3.5

Bar

4.2

Bar

3.5

Bar

17.5-25-12PR

Bias Ply Tire

(Optional)

(60

psi)

(50

psi)

(60

psi)

(50

psi)

The recommended tire pressures are based on the rated load

for each handling case.

In case of heavier loads, especially during loading and carrying

operations, a higher tire pressure is required. Contact the tire

manufacturer for information about which air pressure is the

correct one for the load to be handled and transported over a

particular distance.

If L5 tires are used for loading and carrying operations, due

attention must be paid to the transporting distances. Radial tires

are to be preferred for loading and carrying operation, as the

buildup of heat is less in this type of tire.

Inspection, Maintenance and Adjustment

OP000756

4-85

OP000039

5Transportation

LOADING AND UNLOADING

When transporting the machine observe the various road rules,

road transportation vehicle laws and vehicle limit ordinances, etc.

It is a good idea to obtain special platform for loading and

unloading the machine.

Park the trailer on a flat firm roadbed. Keep a fairly long

distance between the road shoulder and the machine.

Properly apply the brakes of the trailer and place wheel

chocks in front of and behind the tires to ensure that the

trailer does not move.

Fix the ramp in line with the centers of the trailer and the

Figure 1

machine.

Determine the position of the ramp, then slowly load the

machine onto to the specified part of the trailer.

NOTE: Have someone in clear view and in a safe

position, provide directions while loading.

Lower the bucket and lock each control lever using the pilot

cutoff switch.

Apply the parking brake and set the articulation stopper in

the "LOCKED" position.

Tape over the exhaust stack outlet to prevent turbo

"Windmilling" damage.

Place blocks in front of and behind the tires to prevent the

machine from moving.

Fasten the machine to the trailer with chains or cables at

lower part of the rear chassis. Additional chains or cables

may be used but do not damage brake lines or cylinder

rods.

IMPORTANT

Figure 2

Brake pipe runs on axle housing.

Do not fasten axle housing.

10.

Determine the route for transporting the machine by taking

into account the width, height and weight of the machine

and the truck.

Transportation

OP000039

5-1

SUMMARY OF SAFETY

PRECAUTIONS FOR LIFTING

To make safe lifts, the following items must be evaluated by

operator and work site crew.

•

Condition of ground support.

•

Wheel loader configuration and attachments.

•

Weight, lifting height and lifting radius.

•

Safe rigging of load.

•

Proper handling of suspended load.

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

keeping a suspended load secure, if they are anchored safely to_{Figure 3}

control points on ground.

Transportation

OP000039

5-2

OP000040

6Troubleshooting

ENGINE

Problem

Possible Cause

Remedy

Starter does not operate.

Blown fuse.

Replace fuse.

Low battery power.

Charge battery.

Poor terminal contact.

Clean and tighten connections.

Starter switch failed.

Replace switch.

Starter relay failed.

Replace relay.

Starter control failed.

Replace controller.

Wiring harness faulty.

Replace harness.

Battery relay failed.

Replace relay.

Starter engages, engine does

Blown fuse.

Replace fuse.

not start.

Fuel gelled in cold weather.

Replace fuel.

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.

Replace stop control.

Engine stop relay failed.

Replace relay.

Engine starts, runs only at low

Engine oil viscosity incorrect.

Change oil.

speed or shuts down.

Clogged or dirty fuel injectors.

Clean injectors.

Fuel filters plugged.

Replace filters.

Engine stop motor cable out

Readjust.

of adjustment.

Engine speed control cable

Readjust.

out of adjustment.

Engine knocks, runs unevenly

Low engine oil.

Add oil.

or surges.

Plugged air intake system.

Clean system and replace

filter.

Injection pump out of

Contact your DOOSAN dealer.

adjustment.

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.

Troubleshooting

OP000040

6-1

Problem

Possible Cause

Remedy

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

Readjust.

out of adjustment.

Injection pump out of

Contact your DOOSAN dealer.

adjustment.

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 oil cooler.

Oil cooler core plugged.

Clean oil cooler.

Fan belt loose or damaged.

Tighten or replace as required.

Temperature sensor faulty.

Replace sensor.

Engine oil pressure warning

Low engine oil level.

Add oil.

light turns "ON," and buzzer

Wrong grade oil for weather

change oil.

sounds.

conditions.

Clogged oil filter.

Change filter and oil.

Defective alarm switch.

Contact your DOOSAN dealer.

Oil leakage from pipe or joint.

Clogged suction strainer.

Excessive engine wear.

Defective oil pump.

Coolant temp, warning light

Low engine coolant level.

Add coolant.

turns "ON."

Loose/slipping/broken fan belt.

Adjust or replace belt.

Clogged radiator fins.

Clean.

Scale or mineral build up

Flush or professionally clean.

inside radiator.

Defective alarm switch (gauge

Contact your DOOSAN dealer.

is in green).

Low water pump flow.

Thermostat stuck or missing.

Engine does not start when

Fuel filter clogged.

Replace fuel filter.

the starter motor is turning.

Starter motor speed too low.

Booster Battery may be used.

(Also see ELECTRICAL

Defective engine shutoff

Contact your DOOSAN dealer.

TROUBLESHOOTING.)

solenoid.

Fuel pump failure.

Incorrect fuel injection timing.

Compression pressure too low.

Defective injectors.

Troubleshooting

OP000040

6-2

Problem

Possible Cause

Remedy

Unstable (rough) idling.

Air in fuel lines.

Tighten fuel connections and

filter.

Fuel filter clogged.

Replace fuel filter.

Fuel pump failure.

Contact your DOOSAN dealer.

Incorrect fuel injection timing.

Insufficient power.

Air cleaner filter clogged.

Clean or replace element.

Fuel filer element clogged.

Replace fuel filter.

Throttle linkage adjustment

Check and adjust linkage.

wrong.

Engine oil level too high.

Check dipstick and correct

level.

Incorrect valve clearance.

Contact your DOOSAN dealer.

Piston ring wear.

Defective injectors.

Fuel pump failure.

HYDRAULIC SYSTEM

Problem

Possible Cause

Remedy

None of the controls function

Hydraulic pump failed.

Contact your DOOSAN

(loud noise from pumps).

dealer.

Low hydraulic oil level.

Add hydraulic oil as

required.

Suction line plugged or damaged.

Clean or replace as

required.

None of the controls function

Pilot pump failure.

Contact your DOOSAN

(no noise from pumps).

dealer.

Cutoff solenoid valve failed.

Replace solenoid.

Relief cartridge of pilot parking

Clean or replace as

valve stuck.

required.

Safety limit switch is ON.

Adjust limit switch

clearance.

All actuators have low power.

Low hydraulic oil level.

Add hydraulic oil as

required.

Suction filter clogged.

Clean filter.

Hydraulic pumps faulty.

Contact your DOOSAN

dealer.

Main relief pressure too low.

Contact your DOOSAN

dealer.

Hydraulic pumps cavitating.

Bleed air from hydraulic

pumps.

Troubleshooting

OP000040

6-3

Problem

Possible Cause

Remedy

Only one or two actuators

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.

Debris in exterior of cooler.

Clean exterior of cooler.

Oil cooler faulty.

Contact your DOOSAN

dealer.

Fan belt loose.

Tighten fan belting as

required.

Actuators on one side of

Overload relief valve is not

Repair valve or replace.

boom have little power or do

operating properly.

not operate.

Damaged hydraulic hose.

Replace hose.

Loose hydraulic fittings.

Tighten fittings.

Internal damage to control valve

Replace control valve.

housing.

Control valve spool damaged.

Replace control valve.

Sediment inside control valve.

Clean and repair valve.

Check valve internal leakage.

Repair or replace valve.

Damaged cylinder or pump.

Repair or replace pump or

cylinder.

Cylinder internal leakage.

Repair or replace cylinder.

Damaged cylinder rod.

Replace rod.

Pilot valve failure.

Replace pilot valve.

Troubleshooting

OP000040

6-4

TRAVEL SYSTEM

General

Problem

Possible Cause

Remedy

Machine will not travel.

Transmission clutch pressure

Adjust pressure.

incorrect.

Transmission charge pump

Replace pump.

damaged.

Damage to transmission control

Repair wiring.

valve wiring harness.

Burned travel relay or fuse.

Replace relay or fuse.

Forward/Reverse solenoid for

Clean and repair.

transmission control valve sticking.

Damaged transmission clutch.

Repair or replace clutch.

Damaged drive shaft.

Repair or replace.

Damaged transmission or axle.

Repair or replace.

Wheel brakes not releasing.

Repair brakes.

Parking brake not releasing.

Repair parking brake.

Machine will travel but has

Fluid pressure low in transmission

Repair clutch.

little power.

clutch.

Transmission fluid low.

Add fluid.

Damage to torque converter.

Repair or replace.

Engine malfunction.

See Engine

Troubleshooting Table.

Brake valve.

Disassemble and clean.

Unusual transmission noise.

Low transmission fluid, or low

Add fluid or change fluid.

quality fluid.

Worn transmission parts.

Replace parts.

Broken gears or bearings.

Replace parts.

Transmission fails to operate.

Damaged transmission clutch

Replace disks.

disks.

Damaged wires in transmission

Repair wires.

control wire harness.

Drive shaft vibration Noisy

Bent drive shaft.

Replace drive shaft.

universal joints.

Loose universal joints.

Tighten bolts that secure

joints.

Worn or damaged universal joint.

Replace universal joint.

Loose universal joints.

Tighten bolts that secure

universal joints.

Lack of lubrication.

Lubricate universal joints.

Worn slip joint spline.

Replace slip joint.

Noisy Front or Rear Axle.

Worn or broken gears.

Replace gears.

Low oil level, poor quality oil.

Add oil, change oil.

Worn bearings.

Replace bearings.

Worn shaft spline.

Replace spline.

Troubleshooting

OP000040

6-5

STEERING

Problem

Possible Cause

Remedy

Steering Wheel is hard to turn.

Sediment blocking direction

Clean and repair.

change spool orifice, inside priority

valve.

Sediment blocking amplifying spool

Clean and repair.

orifice, inside priority valve.

Sediment blocking load sensing

Clean and repair.

line orifice, inside priority valve.

Priority valve spool sticking, inside

Clean and repair.

steering valve.

Incorrect relief valve pressure

Adjust pressure.

drop, inside priority valve.

Steering pump failure.

Repair or replace.

Leaking steering cylinder.

Repair cylinder.

Rust on steering column bearing

Lubricate.

and spline.

Tire air pressure is low.

Inflate to proper pressure.

High initial resistance to

Air in load sensing line, inside

Bleed system to remove

movement of steering wheel.

priority valve.

air.

Sediment blocking orifice of load

Clean and repair.

sensing line, inside priority valve.

Sediment in direction change

Clean and repair.

spool, inside priority valve.

Damage to control spring damping

Replace priority valve.

inside priority valve.

Steering wheel shakes.

Chattering bearing in axle end

Replace bearing.

differential.

Tire pressure not equal in left side

Equalize pressure.

and right side tires.

Troubleshooting

OP000040

6-6

BRAKING

Problem

Possible Cause

Remedy

Reduced brake action.

Low secondary pressure in brake

Repair or replace brake

valve.

Worn brake disks.

Replace brake disks.

Damaged brake disks.

Replace brake disks.

Damaged brake valve block.

Replace valve.

Air in brake hydraulics due to leak

Repair leak, bleed system.

in brake hose.

After bleeding brakes, brakes

Damaged brake disks.

Replace disks.

are not fully released.

Damaged brake disk return spring.

Replace return springs.

ELECTRICAL SYSTEM

Problem

Possible Cause

Remedy

Battery has no power and will

Damaged battery plates.

Replace battery.

not accept a charge.

Alternator not charging properly.

Repair or replace

alternator.

Bad ground.

Clean and tighten.

Loose electrical connector.

Clean and tighten.

Alternator belt loose or damaged.

Tighten or replace.

Battery will accept a charge

Internal battery short.

Replace battery.

but discharges soon after.

Wiring harness short.

Repair wire.

Troubleshooting

OP000040

6-7

OP000757

7Specification

GENERAL SPECIFICATIONS

DL160

ITEM

SPECIFICATION

Standard Bucket Capacity (BOT / BOC)

1.5 m³ (2.0 yd³) / 1.6 m³(2.1 yd³)

Vehicle Weight (STD / OPT)

8,730 kg (19,246 lb) / 8,760 kg (19,313 lb)

Engine (SAE J1995 Gross)

Emission

U.S EPA Tier3 (EU Stage IIIA)

Maker and Model

Cummins QSB4.5

Type

Turbo Charged, Air to Air Intercooled Direct Injection

Injection System

Common-rail Controlled by Electronic ECM

Max. Horse Power

111 ps (81.7 kw) / 1800 rpm

Rated Horse Power

110 ps (81 kw) / 2000 rpm

Max. Torque

47 kg•m (461 N.m) / 1500 rpm

Transmission

Full Automatic Power -Shift

Full Automatic Power Shift

Speeds

4 Forward, 3 Reverse

Brake Systems

Service Brakes

Full Hydraulic, Separate Dual Line Wet Discs

Parking Brake

Spring Applied / Oil Released on Front Axle, Wet Disc

Performance

Travel Speed

6.6 (4.1) /11.7 (7.3) / 21.4 (13.4) / 34.5 (21.6) km/h (MPH)

Steering Angle

±40°

Min. Tire Turning Radius *

4,859 mm (15' 11")

(Out Tire Edge)

Safe Operating Load

2,560 kg (5,645 lb)

Max. Breakout Force

7,800 kg (17,200 lb)

Boom Rise Time

5.5 ±0.5Sec.

Bucket Dump Time

1.4 ±0.4 Sec.

Boom Down Time

3.3 ±0.4 Sec.

Maximum Gradeability

30° (58%)

Specification

OP000757

7-1

DIMENSION

Doosan DL160. Operation and Maintenance Manual (2008) - page 2