Doosan DL420. Operation and Maintenance Manual (2009)

Grease Steering Cylinder Rod and Head

Ends

Steering cylinder rods, 2 locations, one on each side of

machine.

FG001707

Figure 49

Steering cylinder head ends,

2 locations. Use remote

grease fittings mounted on front frame.(1 and 2, Figure

50).

Remote Grease

Reference Number

Fittings

1 and 2,

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

250 Hours

Center Bearing

FG001708

Figure 50

Grease Upper and Lower Center Pins

Center pins, upper (Figure

51) and lower (Figure 52).

Two locations on right side of machine.

FG001709

Figure 51

FG001710

Figure 52

Inspection, Maintenance and Adjustment

OP000997

4-43

Change Engine Oil and Filter (After First

50 Hours)

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

new machine and every 500 hours thereafter. See

“500 Hour / 3 Month Service” on page 4-50..

Change 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 4-62).

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 4-47.

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 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

FG003903

every 500 hours.

Figure 53

Inspection, Maintenance and Adjustment

OP000997

4-44

Clean Air Conditioner Outer Filter

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

are two filters (1 and 2, Figure 54) 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 54) 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

FG003904

with a new one.

Figure 54

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

OP000997

4-45

250 HOUR / MONTHLY SERVICE

Perform All Daily 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 cleaning or

replacement.

FG014041

Figure 55

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 4-30).

Loosen drain valve from bottom of tank

(Figure

56).

Allow all water and sediment to drain out. Tighten drain

valve.

NOTE: Dispose of drained fluids according to local

regulations.

FG015205

Figure 56

Inspection, Maintenance and Adjustment

OP000997

4-46

Check Air Conditioner and Alternator

Belt Tension

NOTE: 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. After first tension check,

belt must be checked every 250 hours.

Apply 10 kg (22 lb) of force to midpoint of belt. (Figure

57). The belt should deflect

10 mm (0.4 in). If belt

deflects more than this, loosen control link to tighten

belt tension until deflection is

10 mm (0.4 in). Inspect

belt for damage. If belt is damaged, replace it.

FG015221

Figure 57

Grease Drive Shafts

Grease fitting for center bearing,

1 location. Use remote

grease fitting mounted on frame (3, Figure 58).

Remote Grease

Reference Number

Fittings

1 and 2,

Steering Cylinder

50 Hours

Head Ends

Drive Shaft

FG003905

250 Hours

Center Bearing

Figure 58

FG002213

Change Transmission Oil and Filter

Figure 59

(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. (See page 4-66)

NOTE: The transmission must be recalibrated after every oil

change. This is ensure that clutch packs are

engaging properly.See “Transmission Recalibration”

on page 4-104.

Inspection, Maintenance and Adjustment

OP000997

4-47

Clean Outer Filter of Air Cleaner

NOTE: Clean outer filter every

250 hours

/ Monthly of

STOP

F/R

01/04

[FRI]

11:32

service.

524Km

NOTE: If air cleaner clogged warning light (Figure 60) 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.

FG015442

Figure 60

WARNING

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

60) 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

62) from bottom of air cleaner housing cover

(2).

Inspect seal lips for wear or damage. Replace valve if

necessary.

Figure 61

NOTE: Install evacuator valve with lips parallel to the

cover.

Remove the access cover (2, Figure 62) by loosening

the latches (3).

Remove the outer filter (4, Figure 62) from the housing.

Do not remove inner filter (5).

FG000702

Figure 62

Inspection, Maintenance and Adjustment

OP000997

4-48

Clean the outer filter

(4, Figure

62) 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 63

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 64

outer and inner filters. Do not clean inner filter.

Inspection, Maintenance and Adjustment

OP000997

4-49

500 HOUR / 3 MONTH SERVICE

Perform All Daily, 50 and 250 Hour

Service Checks

Change Hydraulic System Brake and

Pilot Filter

Replace filter in pilot filter. Perform the following steps:

Vent hydraulic oil tank.

FG015216

Figure 65

Unscrew element cover (4, Figure 66). Cover is filled

with oil. Dispose of oil.

NOTE: Dispose of drained fluids according to local

regulations.

Remove O-ring (2, Figure 66) and filter (3).

Use a nonflammable, nontoxic solvent to clean out

cover (4, Figure 66).

Insert a new filter (3, Figure 66) into cover (4). Install a

new O-ring (2).

Screw cover (4, Figure 66) onto filter head (1).

FG015227

Figure 66

Inspection, Maintenance and Adjustment

OP000997

4-50

Supplemental Coolant Additive (SCA)

and Antifreeze Concentration

Maintenance Check

Supplemental Coolant Additive (SCA)

Check the SCA concentration level:

•

At least twice a year

•

At every subsequent oil drain interval if the

Figure 67

concentration is above 3 units.

•

Whenever coolant is added to the cooling system

between filter changes.

Use Fleetguard coolant test kit. Part No. CC2602, to check

the SCA concentration level. Instructions are included with

the test kit. Refer to Coolant Recommendations and

Specifications in Maintenance Specifications

(Section V) for

the correct SCA and antifreeze level.

CAUTION

Over concentration of antifreeze or use of high silicate

antifreeze can damage the engine.

Check the antifreeze concentration. Use a mixture of

50%

water and

50% ethylene glycol or propylene glycol based

antifreeze to protect the engine to -32°C [-26°F] year-around.

The Fleetguard refractometer, Part Number C2800, provides

a reliable, easy to read, and accurate measurement of

Figure 68

freezing

point

protection

and glycol

(antifreeze)

concentration.

Antifreeze is essential in every climate.

Antifreeze broadens the operating temperature range by

lowering the coolant freezing point and by raising its boiling

point.

The corrosion inhibitors also protect the cooling system

components from corrosion and prolong component life.

Inspection, Maintenance and Adjustment

OP000997

4-51

Coolant Filter

Replace the coolant filter every time the oil is changed.

[The coolant filter is of the disposable type, i.e. it cannot be

cleaned, but must be replaced.]

Remove

WARNING

Figure 69

Do not remove the pressure cap from a hot engine. Wait

until the coolant temperature is below

50°C

[120°F]

before removing the pressure cap. Heated coolant spray

or steam can cause personal injury.

NOTE: Some engine models do not require coolant filters.

Remove the coolant system pressure cap.

Turn the shutoff valve to the "OFF" position by rotating the

knob from vertical to horizontal in the direction shown.

WARNING

A small amount of coolant can leak when servicing the

coolant filter with the shutoff valve in the "OFF"

position. To reduce the possibility of personal injury,

avoid contact with hot coolant.

WARNING

Figure 70

Coolant is toxic. Keep away from children and pets. If

not reused, dispose of in accordance with local

environmental regulations.

Remove and discard the coolant filter.

Inspection, Maintenance and Adjustment

OP000997

4-52

Install

CAUTION

Do not allow oil to get into the filter. Oil will damage

the DCA.

CAUTION

Mechanical overtightening can distort the threads or

Figure 71

damage the filter head.

Apply a thin film of lubricating oil to the gasket sealing

surface before installing the new coolant filter.

Install the coolant filter on the filter head. Tighten the filter

until the gasket contacts the filter head surface.

Tighten the coolant filter an additional

1/2 to 3/4 of a turn,

or as specified by the filter manufacturer.

CAUTION

The valve must be in the "ON" position to prevent

engine damage.

Turn the shutoff to the "ON" position by rotating the knob

from horizontal to vertical in the direction shown.

Figure 72

Install the coolant system pressure cap.

Figure 73

Inspection, Maintenance and Adjustment

OP000997

4-53

Fuel Filter (Spin-On Type)

General Information

Common Rail Fuel System

The 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.

FG001691

Figure 75

The pressure side main fuel filter have the following

characteristics:

•

10-micron rating

•

engine mounted

FG006240

Figure 76

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.

Figure 77

Inspection, Maintenance and Adjustment

OP000997

4-55

Install

Common Rail Fuel System

CAUTION

Mechanical overtightening can distort the threads and

damage the filter seal or filter canister.

It will be necessary to fill the prefuel filter (suction side) with

fuel by hand priming pump.

Do not fill main

(pressure side) fuel filter with fuel before

Figure 78

installation; instead, prime the fuel system using the fuel lift

pump.

Be sure the center seal ring is installed onto the filter spud.

Install the filter as specified by the filter manufacturer.

Connect the fuel heater, if equipped.

Prime

WARNING

Do not open the high-pressure fuel system with the

engine running. Engine operation causes high fuel

pressure. High-pressure fuel spray can cause serious

injury or death.

Figure 79

Cycle the starter switch and allow the lift pump to run. The

lift pump will run for thirty seconds. Afterwards, turn the

starter switch "OFF" and back "ON" again allowing the lift

pump to run again.

Allow the lift pump to run for three or four, thirty second

cycles before attempting to start the engine.

Finishing Steps

Operate the fuel lift pump to help prime the fuel system.

Turn the starter switch to RUN, but do not attempt to start

FG005764

the engine. This will cause the ECM to operate the fuel lift

Figure 80

pump through a priming cycle which lasts at least thirty

seconds. Cycle the lift pump several times by keying off,

waiting ten seconds and keying back on again.

Once the engine is started, slowly increase the engine

speed while air is purged from the fuel plumbing.

Inspection, Maintenance and Adjustment

OP000997

4-56

Change 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 fuel filter. Drain filter

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

FG001626

1/2 turn more.

Figure 81

NOTE: Coat fuel filter gasket with fuel.

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

OP000997

4-57

Change Fuel Filter

WARNING

Exchange filter after waiting for engine to cool. Be

careful of fire hazards. Do not smoke.

Locate fuel filter inside engine compartment.

Position a small container under fuel filter.

FG015157

Figure 82

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

FG015158

reduce fuel system priming.

Figure 83

Inspection, Maintenance and Adjustment

OP000997

4-58

Turbocharger

The turbocharger is lubricated and cooled through 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 idling 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 84

Inspection, Maintenance and Adjustment

OP000997

4-59

Change Engine Oil and Filter

Change Oil Every 500 Hours

The conditions for the 500 hour interval between oil changes

are that:

•

The oil filter is replaced every time the oil is

changed.

•

The oil filter is a genuine DOOSAN filter.

FG015217

•

The diesel fuel sulphur content does not exceed

Figure 85

0.3% by weight.

•

The oil is of a certain quality grade.

•

The correct oil viscosity for the ambient air

temperature is selected according to diagram.

If any of these conditions are not met, the oil must be

changed and the filters replaced every 250 hours.

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 CH-4 values.

The oil must be changed at least every sixth month,

regardless of the number of operated hours.

Replace the oil filter every time the oil is changed. (The oil

filter is of the disposable type, i.e. it cannot be cleaned, but

must be replaced.).

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.

NOTE: For other duty cycles, see “QSM11 Industrial Engines

Oil Drain Intervals by Duty Cycle

(Hours)” on

page 4-21.

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 engine 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.

Inspection, Maintenance and Adjustment

OP000997

4-60

Replace engine oil filter (Figure 86). Engine oil filter is

a spin-on type (Figure 86). Remove and discard filters.

FG015219

Figure 86

Install new filters.

CAUTION

The lubricating oil filter must be full of oil at

start-up to prevent engine damage.

Use clean 10W40 oil to coat the gasket surface of the filter.

Fill the filter with clean

10W40 oil.

Figure 87

CAUTION

Mechanical overtightening of the filter can distort

the threads or damage the filter seal.

Install the filter on the oil filter head. Tighten the filter

until the gasket contacts the filter head surface. Turn

filters

3/4 - 1 turn more with filter wrench.

NOTE: See

“Fluid Capacities” on page 4-21. for

capacity.

Fill engine with correct oil to the proper level through oil

fill port

(Figure

88). Refer to Lubrication Table of this

manual for recommended oil for the operating conditions.

Start engine and check engine oil pressure warning light.

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

Recheck oil level.

FG015204

Figure 88

Inspection, Maintenance and Adjustment

OP000997

4-61

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.

FG002245

Figure 89

FG002217

Figure 90

Inspection, Maintenance and Adjustment

OP000997

4-62

Clean Air Conditioner Inner Filter

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

are two filters

(1 and 2, Figure 91) 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 91) 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

FG003904

frequently if filter is damaged, replace damaged

with a new one.

Figure 91

WARNING

All service and inspection of the air-conditioning

system must be performed with the starter switch

in the "O" (OFF) position.

Change Axle Differential and Planetaries

Oil (After First 500 Hours)

NOTE: The differential and planetaries oil must be drained

and refilled after first

500 hours of operation or

rebuild, and every 1,500 hours thereafter. (See page

4-75)

Change Air Conditioner Outer Filter

NOTE: Clean air-conditioning outer filter every 50 hours and

replace with a new one every 500 hours of service.

See

“Clean Air Conditioner Outer Filter” on

page 4-45.

Inspection, Maintenance and Adjustment

OP000997

4-63

1,000 HOUR / 6 MONTH SERVICE

Perform All Daily, 50, 250, and 500 Hour

Service Checks

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.

Figure 92

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 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 93

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

“9. Air Cleaner Clogged Warning

Light” on page 2-21.

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

filter or with a damaged one.

Inspection, Maintenance and Adjustment

OP000997

4-64

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

protected from dirt.

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 94

Change Outer Air Cleaner Filter

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.

FG000425

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

Figure 95

Remove evacuator valve (1, Figure 95) and air cleaner

cover (2, Figure 95).

NOTE: Inspect evacuator valve seal lips for wear or

damage. Replace valve if necessary. Install

evacuator valve with lips parallel to the cover.

Remove outer filter (4, Figure 95) 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.

Inspection, Maintenance and Adjustment

OP000997

4-65

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. Follow

procedure under 1,000 hour maintenance interval

(See page 4-44).

NOTE: The transmission must be recalibrated after every oil

change. This is ensure that clutch packs are

engaging properly. See “Transmission Recalibration”

on page 4-104.

Start machine and drive it until transmission fluid has

warmed to 82 - 93°C (180 - 200°F). Park machine on

a level area.

Place transmission lever in "NEUTRAL". Apply parking

brake. Shut down engine. Block tires.

NOTE: See

“Fluid Capacities” on page 4-21. for

capacity.

Open drain valve. Allow all transmission fluid to drain

into a receptacle. Properly dispose of drained fluid.

Clean drain plug.

Close drain valve.

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.

Remove breather filter. Clean breather filter and install

FG015220

it.

Figure 96

Rotate filter counterclockwise to remove it.

Clean filter head.

10.

Grease filter gasket and gasket mating surface on filter

head.

11.

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

filter gasket contacts filter head. Filter must be torqued

to 1.6 - 2.1 kg•m (11.5 - 15 ft lb).

FG002247

Figure 97

Inspection, Maintenance and Adjustment

OP000997

4-66

12. Fill transmission with fluid through fluid supply pipe.

Add fluid until fluid level reaches low mark on dipstick.

13. Start engine. Idle engine for two minutes.

14. With engine idling, check transmission fluid level. Add

fluid until level reaches high mark on dipstick.

15. Idle engine until transmission fluid temperature reaches

82 - 93°C (180 - 200°F). Check fluid level with engine

idling. Level must reach high mark on dipstick.

16. Check filter for leaks while engine is running.

FG003932

Figure 98

Inspection, Maintenance and Adjustment

OP000997

4-67

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.

Open the drain valve (Figure 25) on the bottom of the

fuel tank.

Drain the remaining fuel into a suitable container.

NOTE: Dispose of drained fluids according to local

FG002203

regulations.

Figure 99

Remove bolts, inspection cover and gasket

(Figure

100) from fuel tank.

Clean inside of the tank and suction stainer.

Install the inspection cover with a new gasket. Tighten

the bolts. Do not overtighten.

Close drain valve.

Fill fuel tank.

Check for any leaks at cover and plug.

FG002251

Figure 100

Change 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. The inner 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 4-63.

NOTE: If the equipment is being operated in a dusty

environment, the cleaning and replacement must be

performed more frequently.

Inspection, Maintenance and Adjustment

OP000997

4-68

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.

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 1,500 - 1,800 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.

FG004194

Figure 101

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.

Inspection, Maintenance and Adjustment

OP000997

4-69

Check and Adjust Engine

Contact your nearest DOOSAN loader dealer.

Engine dealer for checking and adjusting the following items:

•

Engine compression pressure.

•

Injection pressure.

•

Injection timing.

Change Air Breather Filter

Position the machine on firm, level ground. Lower the

front attachment to the ground and shut down engine.

Lift the breather cap(2. Figure

102) slightly to release

the internal pressure.

Unscrew the bolt

(1, Figure

102) and take off the

breather cap (2, Figure 102).

Change a filter cartridge (3, Figure 102) and assemble

the breather cap by tighting the bolt.

NOTE: Used filter should always be disposed of

according to local regulations.

FG013207

Figure 102

Inspection, Maintenance and Adjustment

OP000997

4-70

Change 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

1,000 Hours

thereafter.

Loosen breather cap on hydraulic tank. (See Figure 20

on page 4-30).

Clean filter cover

(2, Figure

103) and tank around

cover.

Remove bolts (1, Figure 103) from cover (2).

Lift cover

(2, Figure

103) and O-ring

(4) off tank.

Control spring

(3) that sits beneath cover. Remove

spring (3).

Remove valve (5, Figure 103) and filter (6) from tank.

Clean underside of cover (2, Figure 103).

Set a new element (6, Figure 103) and valve (5) down

FG002240

into tank. Press element down onto its base until top of

Figure 103

element is approximately 4 mm (0.157") below edge of

tank.

Install a new O-ring

(4, Figure

103) on cover (2). Set

spring (3) into place on element (6).

Set cover (2, Figure 103) into place over element (6).

Install bolts

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

10.

Tighten breather cap on tank.

Inspection, Maintenance and Adjustment

OP000997

4-71

1,500 HOUR / 9 MONTH SERVICE

Perform All Daily, 50, 250 and 500 Hour

Service Checks

Change 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. Apply parking

brake. Block wheels.

Clean areas around drain plugs on both ends of axle.

Remove plugs and allow oil to drain into a suitable

container.

NOTE: See

“Fluid Capacities” on page 4-21. for

capacity.

FG002248

NOTE: Dispose of drained fluids according to local

Figure 104

regulations.

NOTE: Plug Size: M24 x 1.5

Tightening Torque: 7.1 kg•m (51 ft lb)

Clean area around level plug (1, Figure 105) and drain

plug

(2) on center differential. Remove level plug

(1)

and drain plug

(2). Allow oil to drain into a suitable

container.

NOTE: Plug Size (1, Figure 105):

M36 x 1.5

Tightening Torque: 13.2 kg•m (95 ft lb)

Plug Size

(2, Figure 105):

M24 x 1.5

FG002249

Tightening Torque: 7.1 kg•m (51 ft lb)

Figure 105 (Front Axle)

Install drain plug (2, Figure 105) into center differential,

and tighten. Install drain plugs on both ends of axle,

and tighten.

Inspection, Maintenance and Adjustment

OP000997

4-72

Pump oil into level plug hole on center differential. Add

oil 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 the level

plug hole, install and tighten level plug.

NOTE: Allow oil time to fill planetaries.

Repeat procedure for other axle.

NOTE: Plug Size (1, Figure 106):

M36 x 1.5

Tightening Torque: 13.2 kg•m (95 ft lb)

Plug Size

(2, Figure 106):

M24 x 1.5

Tightening Torque: 7.1 kg•m (51 ft lb)

FG002250

Figure 106 (Rear Axle)

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.

A wear measurement must be made on both output

sides.

Remove screw plug, actuate brake and determine

"Dimension X" according to Figure 107 and Figure 108

using a feeler gauge. "Dimension X" corresponds with

the thickness of an inner brake disk on the piston side.

FG002219

Figure 107

Inspection, Maintenance and Adjustment

OP000997

4-73

2,000 HOUR / YEARLY SERVICE

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

Hour Service Checks

Change Inner Air Cleaner Filter

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.

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, DriveShaft,

Engine, and Fuel System

Change 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.

Inspection, Maintenance and Adjustment

OP000997

4-75

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:

Start engine and place transmission in "NEUTRAL".

FG002224

Figure 109

Remove plug (Figure 109) on axle. Increase the height

of bleeder

(1, Figure

110) by using special tool

(4,

Figure 110). Place one end of a plastic hose (2, Figure

110) over bleeder screw (1). Place other end of hose

in a container (3) filled with brake fluid.

NOTE: Dispose of drained fluids according to local

regulations.

Station one person in operator's cabin, and one person

at bleeder screw on axle being bled.

Open bleeder screw (1, Figure 110). Then press down

on brake pedal until it rests on floor of cabin. Hold

pedal down on floor of cabin. Close bleeder screw

while pedal is being held down. 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, Figure

110). Install

plug in axle.

Perform bleeding procedure on other three locations.

Figure 110

Inspection, Maintenance and Adjustment

OP000997

4-76

Change 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 4-86., 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

FG003933

performed.

Figure 111

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

CAUTION

Do not mix ethylene glycol and propylene glycol when

changing the antifreez solution. Flushing should be

performed to minimize volume of mixing between the

two columns. Mixing the two compounds may cause

generation of foreign material to damage the system.

Do not mix antifreez solutions from different

manufactures. Mixed solution may degrade the

capabilities of the system. It is recommended to use the

standard product from Doosan.

In the bitterly cold area or weather, the customer should

frequently check the performance of the coolant for

appropriateness for the weather and then determine

change cycle of the coolant.

Inspection, Maintenance and Adjustment

OP000997

4-77

Slowly open the radiator cap (Figure 111) to allow any

pressure to escape.

NOTE: See

“Fluid Capacities” on page 4-21. for

capacity.

Place a container under the radiator and open the

drain plug (1, Figure 112).

NOTE: Dispose of drained fluids according to local

regulations.

Fill cooling system with a flushing solution.

FG0014980

Run engine at low idle until the coolant temperature

Figure 112

gauge reaches the "BLUE ZONE." Run engine for

another ten minutes.

Allow engine to cool.

Drain flushing fluid and fill system with water.

Run engine again to allow water to completely

circulate.

After allowing engine to cool, drain water and fill

system with proper antifreeze mixture for ambient

temperature. Refer to coolant concentration table. See

“Antifreeze Concentration Tables” on page 4-88.

Run engine without radiator cap installed, so that all air

will be purged from system. Fill radiator to fill neck.

10.

Drain and fill radiator coolant recovery tank.

Inspection, Maintenance and Adjustment

OP000997

4-78

Change 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 4-21. for

capacity.

FG014461

Figure 113

Position a catch tank beneath hydraulic tank drain plug.

Open tank breather cap.

(See Figure

20 on page 4-

30). Remove drain plug from bottom of tank.

(Figure

114). Allow all hydraulic oil to drain out.

FG002210

Figure 114

Without starting engine, operate controls to dump

bucket.

(Figure

115). Then operate controls to lower

boom. (Figure 116). This will drain oil out of boom and

bucket cylinders.

Replace full flow hydraulic filters as described under

“Change Hydraulic Full Flow Filter” on page 4-71.

FG014462

Figure 115

FG014463

Figure 116

Inspection, Maintenance and Adjustment

OP000997

4-79

Remove and clean pump inlet strainer

(Figure

117)

inside hydraulic tank.

A. Carefully remove bolts and cover (1, Figure 117)

from top of hydraulic oil tank. There is a spring

(2) under the cover that will force the cover up.

B. Remove spring

(2, Figure

117) and strainer

(4),

by pulling on rod (3).

C. Clean inside and outside of strainer. Replace

strainer if it is broken.

D. Position strainer on boss portion of suction pipe.

FG002244

Install tank drain plug. Refill tank by pouring oil in

Figure 117

through breather cap opening. Install and tighten

breather cap.

Start engine and operate controls to raise and lower

bucket a few times.

(Figure

118). Raise and lower

boom a few times.

(Figure

119). Lower bucket to

ground.

Check tank sight gauge. (See Figure 19 on page 4-30).

Oil level must be between upper limit and lower limit

on sight gauge. Remove breather cap and add oil if

necessary.

FG014464

Figure 118

FG014465

Figure 119

Inspection, Maintenance and Adjustment

OP000997

4-80

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

OP000997

4-81

12,000 HOUR / 6 YEAR SERVICE

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)

European regulations state that the in-service life of any

hydraulic hose may not exceed six years. DOOSAN

recommends the following:

•

Hoses at the customer premises cannot be stored

more than

2 years before being discarded or

installed on a machine.

•

In-service lifetime of hoses fitted on a machine

can never exceed

6 years, but replace hoses

described in

“Change Pipes and Hoses” on

page 4-75, 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

OP000997

4-82

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

mm x std.

4.84

6.92

8.30

mm x

1.0

4.84

7.05

8.30

mm x std.

8.57

11.89

14.52

105

mm x

1.5

9.00

12.59

14.94

108

mm x std.

13.55

18.95

137

23.10

167

mm x

1.5

14.94

108

21.02

152

24.89

180

mm x std.

20.88

151

29.46

213

35.54

257

mm x

1.5

22.54

163

31.53

228

38.03

275

mm x std.

28.90

209

40.52

293

48.41

350

mm x

1.5

32.50

235

45.92

332

55.04

398

mm x std.

40.94

296

57.95

419

69.01

499

mm x

1.5

46.05

333

64.03

463

77.03

557

mm x std.

54.90

397

77.86

563

93.08

673

mm x

1.5

61.00

441

86.02

622

105.00

759

mm x std.

71.00

513

100.00

723

120.00

868

mm x

2.0

78.00

564

109.95

795

130.00

940

mm x

2.0

115.06

832

160.00

1157

195.00

1410

Inspection, Maintenance and Adjustment

OP000997

4-83

ELECTRICAL SYSTEM

Check Battery Condition

WARNING

Before starting any battery service work, make sure to

shut the engine off and turn the starter key to the

"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.

Inspect charge condition of battery by looking at the

indicator light built into battery.

•

GREEN: Normal.

•

BLACK: Insufficient charging - check alternator.

HJB5002L

•

TRANSPARENT: Insufficient battery electrolyte

Figure 120

replace with new battery.

Inspection, Maintenance and Adjustment

OP000997

4-84

ENGINE COOLING SYSTEM

General

Keeping an engine's cooling system in peak operating

condition, can have many benefits to keeping a machine in

good operating condition. A properly functioning cooling

system will; improve fuel efficiency, reduce engine wear, and

extend component life.

Always use distilled water in the radiator. Contaminants in

tap water neutralize the corrosion inhibitor components. If

tap water must be used, it should not exceed

300 ppm

hardness, or contain more than 100 ppm of either chloride

or sulfate. Water that has been treated with a water softener

also contains salt that will cause corrosion of components.

Water from creeks and stagnant pools usually contains dirt,

minerals and/or organic material that are deposited in the

cooling system and impair cooling efficiency. Distilled water

is the best.

Engine overheating is often caused by bent or clogged

radiator fins. The spaces between the fins can be cleaned

by use of air or water under pressure. When straightening

bent fins, use care not to damage the tubes or break the

bond between the fins and the tubes.

WARNING

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

cm²). Always wear goggles when using compressed air.

Do not pour cold water into radiator when engine is

very hot and water level is below the top of the tubes.

Such action could result in damage to engine cylinder

heads.

Heavy duty diesel engines require a balanced mixture of

water and antifreeze. Drain and replace the mixture every

year or

2,000 Hours of operation, which ever comes first.

This will eliminate buildup of harmful chemicals.

Antifreeze is essential in any climate. It broadens the

operating temperature range by lowering the coolant's

freezing point and by raising its boiling point. Do not use

more than 50% antifreeze in the mixture unless additional

freeze protection is required. Never use more than

68%

antifreeze under any condition.

Inspection, Maintenance and Adjustment

OP000997

4-86

Types of Antifreeze

There are two main classifications of antifreeze available on

the market today.

Ethylene Glycol - Doosan Genuine Antifreeze Solution

(for all seasons)

Propylene Glycol - Doosan Genuine Antifreeze Solution

(for all seasons)

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

chemical properties do not provide the improved corrosion

resistance that propylene glycol does. Ethylene glycol is also

very hazardous to the environment, people and animals.

DOOSAN recommends that ethylene glycol be replaced with

propylene glycol.

The newer propylene glycol antifreeze comes in many

different colors. Some of the colors are pink, red, orange

and yellow. There are even some that come in a blue-green

color. The blue-green color makes it very difficult to tell the

difference of what type of antifreeze is in a cooling system.

The colors are only a dye added to the clear antifreeze. Do

not rely on color. Keep careful machine records of what

brand and type of antifreeze is used in the unit. If you are

unsure of what type of antifreeze is in the system, drain and

flush the system.

CAUTION

Do not mix the ethylene glycol and propylene glycol

solutions. If these two chemicals are mixed, undesirable

chemicals may be formed, which damages the

equipment.

Do not mix up the solutions from different

manufacturers. Otherwise, the performance may be

deteriorated. It is recommended to use the Doosan

Genuine Product

In the regions under extreme weather, the user should

determine the performance of the coolant suitable for

the weather condition and decide the replacement cycle.

Inspection, Maintenance and Adjustment

OP000997

4-87

Antifreeze Concentration Tables

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

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

80%

20%

-15°C (5°F)

73%

27%

-20°C (-4°F)

67%

33%

-25°C (-13°F)

60%

40%

-30°C (-22°F)

56%

44%

-40°C (-40°F)

50%

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

(2,000 Hour / Yearly)

Ambient Temperature

Cooling Water

Antifreeze

-10°C (14°F)

78%

22%

-15°C (5°F)

71%

29%

-20°C (-4°F)

65%

35%

-25°C (-13°F)

59%

41%

-30°C (-22°F)

55%

45%

-40°C (-40°F)

48%

52%

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

an absolute standard.

NOTE: Replacement cycle of the Doosan Genuine Product is

2,000 hours or one year.

Inspection, Maintenance and Adjustment

OP000997

4-88

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

FG015214

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

Figure 121

times.

Inspection, Maintenance and Adjustment

OP000997

4-89

HYDRAULIC PRESSURE

CHECKS

Hydraulic pressure for most systems can be check by using

the remote test ports shown in (Figure 123).

Reference

Description

Pressure

TPMLS

Number

TP2

TPSLS

Main Load Sensing Signal

250 ±5 kg/cm²

TP1

Pressure (TPMLS)

(3,625 ±70 psi)

TPP

Steer Load Sensing Signal

185 ±5 kg/cm²

Pressure (TPSLS)

(2,682 ±70 psi)

FG015206

at the only

Figure 123

210 ±5 kg/cm²

steering

Main and

(3,045 ±70 psi)

pump relief

Steering

Pump

at main and

(TPP)

250 ±5 kg/cm²

steering

(3,625 ±70 psi)

pump relief

Transmission Clutch

16 - 18 bar

Pressure (TM)

(232 - 297 psi)

30 +2/-0 bar

Control Lever Activation

(High Idle

Pressure (TP1)

Standard)

Brake Charge Pressure

120 bar above

(TP2)

Main Pump Pressure

Attach gauge to port (1, Figure 123).

Pressure cut off setting for main pump is

250 ±5 kg/

cm²(2,900 ±70 psi).

Adjust screw on main pump pressure regulator (Figure

124). Loosen lock nut and turn screw clockwise to

raise

pressure cut off setting.

Turn screw

counterclockwise to lower pressure cut off setting.

FG001745

Tighten lock nut after pressure has been adjusted.

Figure 124

Inspection, Maintenance and Adjustment

OP000997

4-91

Steering Pump Pressure

Attach gauge to port (2, Figure 123).

Adjust relief valve cartridge on amplifier

(Figure

125).

Cartridge must be adjusted to open at 185 ±5 kg/cm²

(2,680 ±70 psi).

Unscrew remove plug and washer. Adjust screw that is

beneath plug. Turn screw clockwise to raise relief

pressure. Turn screw counterclockwise to lower relief

pressure. One turn varies 65 kg/cm²(925 psi).

Figure 125

Install plug and washer after pressure has been

adjusted.

Transmission Clutch Pressure

Attach gauge to port (4, Figure 123).

It is not impossible to adjust pressure.

NOTE: Transmission clutch pressure is 18 - 20 kg/cm²

(256 - 284 psi).

Brake Charge Pressure

Attach gauge to port (6, Figure 123).

Adjust relief valve cartridge on brake and pilot and fan

motor supply valve

(Figure

126). Relief pressure

(Figure

126) for brake charging is

120 ±5 kg/cm²

(1,740 ±70 psi).

FG015207

Figure 126

Control Lever Activation Pressure

Attach gauge to port (5, Figure 123).

Adjust relief cartridge

(Figure

127) on brake and pilot

and fan motor supply valve. Relief pressure must be

set at 30 - 32 kg/cm² (435 - 464 psi).

Loosen lock nut on adjusting screw. Turn adjusting

screw clockwise to raise relief pressure. Turn adjusting

screw counterclockwise to lower relief pressure.

FG015208

Tighten lock nut after adjustment has been made.

Figure 127

Inspection, Maintenance and Adjustment

OP000997

4-92

Fan Motor Pressure and Fan rpm

By the motor intergrated proportional pressure relief valve,

the fan speed (and therewith the cooling performance) can

be infinitely controlled in dependence on two different

simultaneously input signals from temperature sensors.

The cooling fan controller processes the 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 at interrupted voltage supply

(e.g. broken wire). This results in a max. fan speed and

therefore in a max. cooling performance.

Standard

Fan Motor Pressure

140+5/-0 kg/cm²(2,030 +70/-0 psi)

Fan rpm

1,200

FG001746

Figure 129

Reference

Description

Number

Engine

Cooling Fan

Brake and Pilot Pump

Temperature Sensor (T/M Oil)

Cooler

Temperature Sensor

(Coolant Water)

Cooling Fan Controller

Transmission

Fan Motor

Inspection, Maintenance and Adjustment

OP000997

4-94

Checking the Relief Pressure of Fan

Motor

FG001747

Figure 130

Reference

Description

Number

Fan Motor

Drain Line

Fan Guard

Outlet Line

Inlet Line

Relief Valve

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

pressing in towards the end position of accelerator

pedal and reading the pressure in the gauge. Maximum

fan motor pressure: 140 ±2 kg/cm² (The fan speed is

approximately 1,200 rpm at this time)

If fan speed requires adjusting, shut down engine and

adjust a C6 relief of the brake, pilot and fan motor

supply valve.

Inspection, Maintenance and Adjustment

OP000997

4-95

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

OP000997

4-96

PARKING BRAKE

ADJUSTMENT

Emergency Release of the Parking

Brake

Special design with

extended guide bolt

FG008053

Figure 131

If the parking brake cannot be released by normal hydraulic

system pressure, or if the engine will not start, it must be

manually released before towing can take place.

Before releasing parking brake make sure that wheels

have wheel chocks placed in front of and behind them,

to prevent machine from moving when parking brake is

released.

2876A

Figure 132

Inspection, Maintenance and Adjustment

OP000997

4-97

Release the screw cap (6, Figure 131) and unscrew.

Release the lock nut

(5, Figure

131) and turn the

adjusting screw

(4) counterclockwise until the brake

disk is free.

Install lock nut

(5, Figure 131) and screw cap (6) and

tighten both as far as possible. This will protect the

parking brake assembly from dirt.

NOTE: Now, the vehicle does not have any brake

function. The vehicle must be secured against

moving away with proper means. Before putting

the vehicle into operation again, the brake has

Figure 133

to be adjusted according to adjusting

regulations.

Adjusting regulations

During this adjusting process, the parking brake must be

released, i.e. the bank of cup springs (3, Figure 131) must

be completely pretensioned.

Park vehicle on an even surface and place wheel

chocks in front of and behind tires. Only then release

the parking brake.

Release the screw cap (6, Figure 131) and unscrew.

Release the lock nut

(5, Figure

131) (size

24 or 30)

and turn the adjusting screw

(4) with socket wrench

(size

8 or 10) clockwise until the two brake pads

(1)

and (2) make contact with the brake disk.

Turn the adjusting screw

(4,

Figure

131)

counterclockwise and set the clearance specified in the

following table.

Type

Adjusting Screw

Clearance (mm)

Revolutions

min.

0.5

1/4

Small

M 16 (size 8)

Rated clearance

1.0

1/2

max

1.5

3/4

min.

1.0

2/5

Large

M 20 (size 10)

Rated clearance

2.0

4/5

max

3.0

1 1/5

Hold the adjusting screw

(4, Figure

131) in position

with the hexagonal socket wrench and lock with the

lock nut (5).

Mount the screw cap (6, Figure 131) and tighten as far

as possible manually.

Actuate the brake valve several times and check the

braking efficiency of the parking brake on slope.

Inspection, Maintenance and Adjustment

OP000997

4-98

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

OP000997

4-99

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 4-103)

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.

Inspection, Maintenance and Adjustment

OP000997

4-100

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).

Wheel Nut Torque

Tighten wheel nuts to 85 kg•m (615 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 134.

Figure 134

Inspection, Maintenance and Adjustment

OP000997

4-101

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

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

Tread

the tires must be replaced with new tires.

For the replacement contact DOOSAN loader dealer or a

Side walls

tire manufacturer's local dealer.

Breakers

Carcass

•

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.

Beads/Bead wire

FG014479

•

Damage to the carcass exceeds

1/3 of the tire

Figure 135

width.

•

Tire layers are separated.

•

Radial cracks reach the carcass.

•

Deformation or damage which makes the tire

unsuitable for use.

Inspection, Maintenance and Adjustment

OP000997

4-102

Recommended Air Pressure

Working Pressure

Driving Pressure

Tire

Remarks

Front Tire

Rear Tire

Front Tire

Rear Tire

+0.1

4.1

Bar

3.5

Bar

4.1

Bar

3.5

Bar

Bias Ply Tire

(60

psi)

(50

psi)

(60

psi)

(50

psi)

+0.1

3.5

Bar

3.0

Bar

3.5

Bar

3.0

Bar

Radial Ply Tire

(50

psi)

(44

psi)

(50

psi)

(44

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

OP000997

4-103

TRANSMISSION

RECALIBRATION

The recalibration of the transmission clutches and the

electronics of the transmission must be performed at specific

times. ZF has developed an easy tool

(Figure

136) to

perform this task, the AEB Starter, part number

0501-211-778.

It is recommended that AEB Starter be run when:

Oil is changed in the transmission per operator's

manual.

Replacement of the Transmission Control Unit (TCU).

Replacement of the transmission.

Figure 136

If there is a problem with the shifting quality of the

transmission.

The AEB Starter has the task to compensate tolerances

(plate clearance and pressure levels) which are influencing

the filling procedure of the clutches. For each clutch, the

correct filling parameters are determined in one cycle for:

Period of the quick-filling time.

Level of the filling compensating pressure.

The filling parameters are stored, with the AEB Program and

the driving program, in the Transmission Control Unit (TCU).

Since the TCU is a separate component, the AEB-cycle

must be started only after the installation of transmission

and TCU in the machine, thus insuring the correct

programing between the transmission and the electronics.

No.

Order

Display Message

Remark

Warm transmission to operating

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

temperature.

Turn off starter switch key.

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

Plug AEB Starter into connector located

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

under the seat. See Figure 136

Put transmission gear selector lever in

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

the neutral position.

Engage the parking brake.

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

TCU must recognize "PL"

for

2 sec. before you

Starter engine.

"PL"

press the AEB Starter

button.

Only idle the machine.

"PL"

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

Inspection, Maintenance and Adjustment

OP000997

4-104

No.

Order

Display Message

Remark

The button must not be

released before TCU has

Press the button of the AEB Starter.

"ST"

started the AEB or quit

with an error code.

Release the button TCU

has started the AEB and

Hold button until AEB has been started.

"K1"

goes on adjusting K1,

K2,…KR.

AEB has been

Wait until the AEB Starter has finished.

"OK"

successful.

Turn off ignition and unplug AEB.

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

Symbol

Meaning

Remarks

AEB - Starter is plugged at the

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

diagnostic plug.

AEB - Starter button is pressed.

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

Calibrating clutch K1... K4, KV or

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

K1… KV, KR

KR resp.

Wait for start, initialization of

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

+ Kx

clutch Kx.

1, 2, 3, 4, V, R

Fast fill time determination of

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

+ Kx

clutch Kx.

Compensating pressure

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

+ Kx

determination of clutch Kx.

Calibration for all clutches

Transmissions stays in neutral, you

finished

have to restart the TCU (ignition off/

on) after removing AEB-starter

AEB canceled (activation stopped)

Transmissions stays in neutral, you

STOP

have to restart the TCU (ignition off/

on)

AEB stopped, clutch Kx cannot

Transmissions stays in neutral, you

STOP + Kx

be calibrated.

have to restart the TCU (ignition off/

on)

Kx couldn't be calibrated, AEB

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

finished

+ Kx

Engine speed too low.

Raise engine speed.

+ E

Engine speed too high.

Lower engine speed.

+ E

Transmission oil temperature too

Heat up transmission.

+ T

low.

Transmission oil temperature too

Cool down transmission.

+ T

high.

Inspection, Maintenance and Adjustment

OP000997

4-105

Symbol

Meaning

Remarks

Transmission temperature not in

Transmissions stays in neutral, you

defined range during calibration

have to restart the TCU (ignition off/

on)

Operating mode not NORMAL or

Transmissions stays in neutral, you

transmission temperature sensor

have to restart the TCU (ignition off/

defective or storing of calibrated

on)

values to EEPROM has failed.

Output speed not zero

Transmissions stays in neutral, you

have to restart the TCU (ignition off/

on)

Shift lever not in neutral position

Transmissions stays in neutral, you

have to restart the TCU (ignition off/

on)

Park brake not applied

Transmissions stays in neutral, you

have to restart the TCU (ignition off/

on)

AEB - Starter was used incorrect

Transmissions stays in neutral, you

STOP

or is defective. Wrong device or

have to restart the TCU (ignition off/

wrong cable used.

on)

Inspection, Maintenance and Adjustment

OP000997

4-106

OP000045

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

2880A

the trailer does not move.

Figure 137

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

the 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.

Side

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.

2882A

IMPORTANT

Figure 138

Brake pipe runs on axle housing.

Do not fasten axle housing.

Transportation

OP000045

5-1

10. Determine the route for transporting the machine by

taking into account the width, height and weight of the

machine and the truck.

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

Figure 139

safely to control points on ground.

Transportation

OP000045

5-2

OP000046

6Troubleshooting

BRAKING

Problem

Cause

Remedy

Reduced brake action.

Low secondary pressure in brake

Repair or replace brake valve.

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

Repair leak, bleed system.

leak in brake hose.

After bleeding brakes, brakes are

Damaged brake disks.

Replace disks.

not fully released.

Damaged brake disk return

Replace return springs.

spring.

ELECTRICAL SYSTEM

Problem

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 but

Internal battery short.

Replace battery.

discharges soon after.

Wiring harness short.

Repair wire.

Troubleshooting

OP000046

6-1

ENGINE

Problem

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 not

Blown fuse.

Replace fuse.

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 of

Readjust.

adjustment.

Engine speed control cable out

Readjust.

of adjustment.

Engine knocks, runs unevenly or

Low engine oil.

Add oil.

surges.

Plugged air intake system.

Clean system and replace filter.

Injection pump out of adjustment.

Contact your DOOSAN dealer.

Plugged fuel filter.

Replace fuel filter.

Water or dirt in fuel system.

Clean system and add new fuel.

Clogged or dirty fuel injectors.

Clean injectors.

Troubleshooting

OP000046

6-2

Problem

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 out

Readjust.

of adjustment.

Injection pump out of adjustment.

Contact your DOOSAN dealer.

Valve backlash faulty.

Adjust backlash.

Engine runs hot.

Low coolant level.

Add coolant.

Thermostat faulty.

Replace thermostat.

Radiator cap faulty.

Replace radiator cap.

Radiator core plugged.

Clean 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 light

Low engine oil level.

Add oil.

turns "ON", and buzzer sounds.

Wrong grade oil for weather

change oil.

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 turns

Low engine coolant level.

Add coolant.

"ON".

Loose/slipping/broken fan belt.

Adjust or replace belt.

Clogged radiator fins.

Clean.

Scale or mineral build up inside

Flush or professionally clean.

radiator.

Defective alarm switch (gauge is

Contact your DOOSAN dealer.

in green).

Low water pump flow.

Thermostat stuck or missing.

Troubleshooting

OP000046

6-3

Problem

Cause

Remedy

Engine does not start when the

Fuel filter clogged.

Replace fuel filter.

starter motor is turning. (Also

Starter motor speed too low.

Booster Battery may be used.

see ELECTRICAL

TROUBLESHOOTING.)

Defective engine shutoff

Contact your DOOSAN dealer.

solenoid.

Fuel pump failure.

Incorrect fuel injection timing.

Compression pressure too low.

Defective injectors.

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 clogged.

Clean or replace element.

Fuel filer 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

Cause

Remedy

None of the controls function

Hydraulic pump failed.

Contact your DOOSAN dealer.

(loud noise from pumps).

Low hydraulic oil level.

Add hydraulic oil as required.

Suction line plugged or

Clean or replace as required.

damaged.

Troubleshooting

OP000046

6-4

Problem

Cause

Remedy

None of the controls function (no

Pilot pump failure.

Contact your DOOSAN dealer.

noise from pumps).

Cutoff solenoid valve failed.

Replace solenoid.

Relief cartridge of pilot parking

Clean or replace as required.

valve stuck.

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.

Only one or two actuators have

Overload relief pressure too low.

Reset pressure.

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.

Troubleshooting

OP000046

6-5

Problem

Cause

Remedy

Actuators on one side of boom

Overload relief valve is not

Repair valve or replace.

have little power or do not

operating properly.

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.

STEERING

Problem

Cause

Remedy

Steering Wheel is hard to turn.

Sediment blocking direction

Clean and repair.

change spool orifice, inside

priority valve.

Sediment blocking amplifying

Clean and repair.

spool orifice, inside priority valve.

Sediment blocking load sensing

Clean and repair.

line orifice, inside priority valve.

Priority valve spool sticking,

Clean and repair.

inside 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.

Troubleshooting

OP000046

6-6

Problem

Cause

Remedy

High initial resistance to

Air in load sensing line, inside

Bleed system to remove air.

movement of steering wheel.

priority valve.

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

Replace priority valve.

damping inside priority valve.

Steering wheel shakes.

Chattering bearing in axle end

Replace bearing.

differential.

Tire pressure not equal in left

Equalize pressure.

side and right side tires.

Troubleshooting

OP000046

6-7

TRAVEL SYSTEM

General

Problem

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 little

Fluid pressure low in

Repair clutch.

power.

transmission 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.

Troubleshooting

OP000046

6-8

Problem

Cause

Remedy

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

OP000046

6-9

OP000998

7Specification

GENERAL SPECIFICATIONS

DL420

ITEM

SPECIFICATION

Standard Bucket Capacity (BOT / BOC)

4.00 m³ (5.23 yd³) / 4.20 m³ (5.50 yd³)

Vehicle Weight

22,300 kg (49,163 lb)

Engine (SAE J1995 Gross)

Emission

U.S EPA Tier3 (EU Stage IIIA)

Maker and Model

Cummins QSM11 Tier-3

Type

Turbo Charged, Air to Air Intercooled Direct Injection

Injection System

Common-rail Controlled by Electronic ECM

Max. Horse Power

314 ps (231 kw) / 1,700 rpm

Rated Horse Power

284 ps (209 kw) / 2,000 rpm

Max. Torque

148 kg•m (1,450 N.m) / 1,400 rpm

Transmission

Full Automatic Power -Shift

Full Automatic Power Shift

Speeds

4 Forward, 3 Reverse

Brake Systems

Travel Brakes

4 Wheel, Wet Disk (Sinter Metal Disk)

Parking Brake

SAHR, Dry Disk Type

Performance

Travel Speed

6.5 (4.0) /12.4 (7.7) / 18.4 (11.4) / 38 (22.8) km/h (MPH)

Steering Angle

±40°

Min. Tire Turning Radius

5,958 mm (19' 7")

(Out Tire Edge)

Safe Operating Load

7,200 kg (15,873 lb)

Max. Breakout Force

21,200 kg (46,738 lb)

Boom Rise Time

5.8 ±0.4 s

Bucket Dump Time

1.4 ±0.3 s

Boom Down Time

3.0 ±0.4 s

Maximum Gradeability

26° (49%)

Specification

OP000998

7-1

DL420 HIGH LIFT

ITEM

SPECIFICATION

Standard Bucket Capacity (BOC)

4.2 m³(5.46 yd³)

Vehicle Weight

23,740 kg (52,337 lb)

Engine (SAE J1995 Gross)

Emission

U.S EPA Tier3 (EU Stage IIIA)

Maker and Model

Cummins QSM 11

Type

Turbo Charged, Air to Air Intercooled Direct Injection

Injection System

Common-rail Controlled by Electronic ECM

Max. Horse Power

314 ps (231 kw) / 1700 rpm

Rated Horse Power

284 ps (209 kw) / 2000 rpm

Max. Torque

148 kg•m (1,450 N.m) / 1400 rpm

Transmission

Full Automatic Power -Shift

Full Automatic Power Shift

Speeds

4 Forward, 3 Reverse

Brake Systems

Travel Brakes

4 Wheel, Wet Disk (Sinter Metal Disk)

Parking Brake

SAHR, Dry Disk Type

Performance

Travel Speed

6.5 (4.0) /12.4 (7.7) / 18.4 (11.4) / 38 (22.8) km/h (MPH)

Steering Angle

±40°

Min. Tire Turning Radius

6,350 mm (20' 10")

(Out Tire Edge)

Safe Operating Load

6,740 kg (14,859 lb)

Max. Breakout Force

20,500 kg (45,195 lb)

Boom Rise Time

5.8 ±0.5 s

Bucket Dump Time

1.4 ±0.4 s

Boom Down Time

3.0 ±0.4 s

Maximum Gradeability

30° (58%)

Specification

OP000998

7-2

Doosan DL420. Operation and Maintenance Manual (2009) - page 3