Doosan DX480LC, DX520LC. Operation and Maintenance Manual (2009)

TABLE OF RECOMMENDED

LUBRICANTS

IMPORTANT

It is highly recommend to use the Doosan Genuine

Products, or products which meet the specification below.

Using other products may damage the equipment.

NOTE:

Refer to the Maintenance Intervals Table for

application points.

Ambient Temperature

Kind of

-22

-4

104

122

Reservoir

Fluid

°F

-30

-20

-10

50 °C

SAE 10W-30

Engine Oil

* SAE 10W-40

Pan

Engine Oil

SAE 15W-40

Swing Drive

SAE 90 and API GL5

Case

Gear Oil

* SAE 80W-90 and API GL5

Final Drive

Case

SAE 140 and API GL5

ISO VG 32

***

Hydraulic Oil

Hydraulic

* ISO VG 46

Tank

Oil

ISO VG 68

* ASTM D975 No. 2

Fuel Tank

Diesel Fuel

ASTM D975 No. 1

Inspection, Maintenance and Adjustment

OP000812

4-6

Grease

* Multipurpose Lithium Grease NLGI No. 2

Fitting

Cooling

Add Antifreeze

Coolant

System

* (50% antifreeze - 50% distilled water)

Installed at factory.

Engine oil must meet ACEA-E5 or API-CI-4.

*** Hydraulic oil change interval is 2,000 hours, only when DOOSAN Genuine Oil is used. If other brands of

oil is used, guaranteed change interval is 1,000 hours. Note that the mixing ratio is for reference purpose

only, and is not an absolute standard.

API: American Petroleum Institute.

ACEA: Association des Constructeurs Europens d’Automobiles.

ASTM: American Society of Testing and Material.

ISO: International Standardization Organization.

NLGI: National Lubricating Grease Institute.

SAE: Society of Automotive Engineers.

CAUTION

Do not mix oils from different manufacturers. DOOSAN

does not endorse specific brands but does suggest that

owners select quality oils whose suppliers provide assurance

that required standards will always be met or exceeded.

IMPORTANT

Fluctuating daily or weekly extremes of temperature, or

operation in subzero freezing weather may make it

impractical to use straight weight lubricants. Use good

judgment in selecting lubricant types that are appropriate

for climate conditions.

OP000812

Inspection, Maintenance and Adjustment

4-7

FLUID CAPACITIES

Component

Capacity

44 liters

Oil Pan with Filter

(11.6 U.S. gal.)

Engine

40 liters

Cooling System

(10.6 U.S. gal.)

620 liters

Fuel Tank

(164 U.S. gal.)

265 liters

Tank Level

(70 U.S. gal.)

Hydraulic Oil

500 liters

System

(132 U.S. gal.)

6 liters

Travel Reduction Device (Each)

(1.6 U.S. gal.)

4 liters

Swing Device (Each)

(1.1 U.S. gal.)

LUBRICATION AND SERVICE

CHART

Lubrication and service chart is on the inside of battery box

cover. The symbols shown here are used in the lubrication and

service chart on the next page.

Symbol

Description

Symbol

Description

Lubrication

Hydraulic Oil Tank Breather

Gear Oil (Swing Device, Travel Device)

Coolant

Engine Oil

Air Cleaner Element

Engine Oil Filter

Fuel Filter

Hydraulic Oil

Air Conditioner Filter

Hydraulic Oil Return Filter

Drain Water

Inspection, Maintenance and Adjustment

OP000812

4-8

SERVICE DATA

Qty.

Service Interval

No.

Items to Check

Service

250

500

1000

2000

Arm, Bucket Joint Pin

Grease

F100

W10

Boom, Arm Joint Pin

Grease

F100

W10

Swing Bearing

Grease

W10

Swing Gear

Grease

Swing Reduction Gear

Grease

W10

Gear Oil

Swing Device

2X4 L

(80W90)

Track Spring

Grease

W10

Travel Reduction

Gear Oil

2X6 L

F, V

Device

(80W90)

Engine Oil

44 L

(10W40)

Hydraulic Oil Tank

Hydraulic Oil

500 L

Fuel Tank

Diesel

620 L

Fuel Prefilter

Cartridge

Coolant

Radiator

40 L

(Antifreeze)

Hydraulic Oil Return

Element

Filter

Pilot Filter

Element

Hydraulic Oil Suction

Strainer

Engine Oil Filter

Cartridge

Fuel Filter

Cartridge

Air Cleaner (Outer)

Element

Air Cleaner (Inner)

Element

Air Conditioner Filter

Cartridge

(Outer)

Air Conditioner Filter

Cartridge

(Inner)

Air Breather Filter

Cartridge

V: Maintenance and Refill.

C: Cleaning.

F: First Time Exchange Only.

F100: Every 10 Hours For First 100 Hours.

W10: Every 10 Hours If Operating In Water.

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

“Engine Cooling System” on page 4-78, for further explanation.

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

“Engine Cooling System” on page 4-78, for further explanation.

: Replacement On Every Interval.

NOTE:

For additional service items see list of “Maintenance Intervals” on page 4-12.

OP000812

Inspection, Maintenance and Adjustment

4-11

MAINTENANCE INTERVALS

SERVICE ITEM

PAGE

10 Hour / Daily Service

Grease Boom, Arm and Front Attachment Pins (for first 100 hours)

4-14

Check Engine Oil Level

4-14

Check Level of Hydraulic Oil Tank

4-15

Check for Leaks in Hydraulic System

4-16

Check Fuel Level

4-17

Check for Leaks in Fuel System

4-17

Check Fuel Prefilter and Drain Water As Required

4-18

Check Oil Level of Swing Reduction Device

4-19

Clean Dust Net in Front of Oil Cooler and Intercooler

4-20

Check Cooling System and Refill As Required

4-21

Check Level of Window Washer Liquid

4-21

Inspect the Bucket Teeth and Side Cutters for Signs of Wear

4-22

Inspect Engine Fan Blade

4-22

Check Air Intake System

4-23

Inspect Seat Belt for Proper Operation

4-23

Inspect the Structure for Cracks and Faulty Welds

4-23

Check the Operation of All Switches

4-23

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

4-24

Lights

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

4-24

Operating Temperature. Listen for Any Abnormal Sounds

Check Operation of All Controls

4-24

50 Hour / Weekly Service

Perform All Daily Service Checks

4-25

Grease Arm and Bucket Joint Pins

4-25

Grease Swing Bearing

4-26

Drain Water and Sediment from Fuel Tank

4-27

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

4-27

Change Engine Oil and Filter (After First 50 Hours)

4-27

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

4-27

(Links, Shoes, Rollers, Idlers)

250 Hour / Monthly Service

Perform All Daily and 50 Hour Service Checks

4-28

Grease Boom and Arm Joint Pins

4-28

Check Engine Fan Belt Tension

4-30

Check Engine Fan Belt Wear

4-31

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

4-32

Change Breaker Filter Element (Optional)

4-32

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

4-33

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

4-33

Replace Hydraulic Oil Return Filter (After First 250 Hours)

4-33

Change Pilot Filter (After First 250 Hours)

4-33

Inspection, Maintenance and Adjustment

OP000812

4-12

Inspect Pins and Bushings of the Front End Attachments for Signs of Wear

4-33

Check Fluid Levels in Batteries and Battery Charge Levels

4-33

Inspect for Any Loose or Missing Nuts and Bolts

4-33

Inspect Fuel System Hose Clamps

4-33

500 Hour / 3 Month Service

Perform All Daily, 50 and 250 Hour Service Checks

4-34

Grease Swing Gear and Pinion

4-34

Change Engine Oil and Filter

4-35

Clean Air-Conditioning Outer Filter

4-36

Check and Clean Air-Conditioning Inner Filter

4-37

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

4-38

Clean Outer Filter of Air Cleaner

4-39

Change of Fuel Prefilter

4-41

Change Fuel Filter

4-42

1,000 Hour / 6 Month service

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

4-43

Grease Swing Reduction Device

4-43

Replace Hydraulic Oil Return Filter

4-44

Change Pilot Filter

4-45

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

4-46

Change Air Breather Filter

4-46

Change Air-Conditioning Outer Filter

4-47

Check Air Conditioner Refrigerant

4-48

Check and Adjust Engine **

4-48

2,000 Hour / Yearly Service

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

4-49

Change Swing Reduction Device Oil

4-49

Replace Outer and Inner Air Cleaner Elements

4-50

Change Radiator Coolant

4-51

Hydraulic Oil Exchange and Suction Strainer Cleaning

4-52

Check Alternator and Starter**

4-54

Check All Rubber Antivibration Shock Mounts

4-54

Perform and Record the Results of the Cycle Time Tests

4-54

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

4-54

Check, Adjust Valve Clearance **

4-54

Check Head Bolt Torques

4-54

4,000 Hour / Biennial Service

Major Parts - Periodic Replacement

4-55

12,000 Hour / Year Service

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

4-56

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

OP000812

Inspection, Maintenance and Adjustment

4-13

10 HOUR / DAILY SERVICE

Grease Boom, Arm and Front Attachment

Pins (for first 100 hours)

WARNING

Do not remove the grease fitting until the pressure is

entirely bleed off by loosening grease fitting slowly to avoid

fatal wound.

Let anybody never be in the blowing direction.

FG000500

Figure 13

Be careful to any kinds of works for nipples and hydraulic

line plugs.

Grease every 10 hours for first 100 hours and every 50 or 250

hours thereafter (See page 4-25).

NOTE:

If the unit has been running or working in water the

front attachment should be greased on a 10 hour /

daily basis.

Check Engine Oil Level

WARNING

Allow the engine to cool before checking the oil level to

avoid burns by touching hot engine parts.

NOTE:

When checking level using a dipstick always remove

and wipe it clean before making final level check.

FG001504

Shut down engine and wait for fifteen minutes. This will

Figure 14

allow all oil to drain back to oil pan.

Remove dipstick (1, Figure 14) and wipe the oil off with a

clean cloth.

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

again.

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

marks on dipstick.

NOTE:

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

must be drained to return oil to proper level.

Add oil through engine oil fill cap (2, Figure 14), if the oil

level is below the "LOW" mark.

FG000616

Figure 15

Inspection, Maintenance and Adjustment

OP000812

4-14

Check Level of Hydraulic Oil Tank

WARNING

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool before attempting to

service any of the hydraulic components.

The hydraulic tank is pressurized. Lift the breather cap

slowly to allow the pressurized air to vent. After the

ARO1760L

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

Figure 16

fill cap or service covers.

Position the machine on firm, level ground. Lower boom

and position bucket on ground as shown in Figure 17.

Set engine speed to "LOW IDLE."

FG001378

Figure 17

Set safety lever to "LOCK" position.

Check level gauge by opening right access door. Oil level

must be between marks on sight gauge.

FG001505

Figure 18

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

Shut down engine.

The hydraulic tank is pressurized. Lift the breather

cap slowly to allow the pressurized air to vent.

Remove the upper cover of the hydraulic tank and

add oil.

IMPORTANT

FG001506

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

Figure 19

can result in damage to equipment and oil leaking

from hydraulic tank due to expansion.

OP000812

Inspection, Maintenance and Adjustment

4-15

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

Shut down engine and wait for the hydraulic oil to

cool down.

Drain the excess oil from drain plug (Figure 20) at the

bottom of the tank into a suitable container, using a

hose at the point (plug).

NOTE:

Dispose of drained fluids according to local

regulations.

FG014361

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.

Inspection, Maintenance and Adjustment

OP000812

4-16

Check Fuel Level

WARNING

Use extreme safety precautions while refueling to prevent

explosions or fire.

Immediately clean up any split fuel.

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

fill tube (1, Figure 21). When working at a temperature of

FG001510

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

Figure 21

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

equivalent.

Make sure that the fuel fill hose is grounded to the

excavator before fueling begins.

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

tank sight gauge (2, Figure 21).

NOTE:

See “Fluid Capacities” on page 4-8. for

capacity.

The excavator may be equipped with the optional battery

operated fuel fill pump. The pump assembly is in the

hydraulic pump compartment. Put the suction hose of the

pump into the fuel resupply tank. Turn the switch in the

pump compartment "ON," and the fuel will be pumped into

the excavator fuel tank.

NOTE:

See “Fuel Transfer Pump (Optional)” on

page 4-83, for further information.

Do not overfill the tank.

Securely tighten cap after fueling.

NOTE:

If breather holes (3, Figure 22) in cap are

clogged, a vacuum may form in the tank

preventing proper fuel flow to engine. Keep

holes in fuel cap clean.

FG000317

Figure 22

Check for Leaks in Fuel System

Perform an inspection of the engine compartment to verify

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

determine the source of the leak and repair.

OP000812

Inspection, Maintenance and Adjustment

4-17

Check Fuel Prefilter and Drain Water As

Required

NOTE:

If water in fuel warning light (Figure 22) on instrument

panel comes "ON", drain the collected water in fuel

prefilter.

FG013894

Figure 23

A fuel prefilter is inside the left rear side access door.

Open the access door on left rear side of the machine.

FG002080

Figure 24

It is necessary to drain the collected water if the bowl is full

of water or sediment.

Position a small container under fuel prefilter. Drain water

or sediment by opening drain valve (2, Figure 25) on

bottom of bowl (1).

NOTE:

Dispose of drained fluids according to local

regulations.

Close drain valve.

open

FG000438

Figure 25

Inspection, Maintenance and Adjustment

OP000812

4-18

Check Oil Level of Swing Reduction

Device

WARNING

The gear oil is very hot after the machine has been

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

Before fully removing any motor case inspection port plug,

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

escape.

NOTE:When checking level using a dipstick always

FG001520

remove and wipe it clean before making final

Figure 26

level check.

Remove dipstick (1, Figure 26) and wipe the oil from the

dipstick with a cloth.

Insert dipstick (1, Figure 26) fully into dipstick tube.

When dipstick is pulled out, oil level must be between

"HIGH" and "LOW" marks on dipstick.

NOTE:

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

must be drained to proper level.

If the oil does not reach the "L" mark on the dipstick, add oil

through fill port (2, Figure 26).

FG000419

Figure 27

If the oil level exceeds the "H" mark on the dipstick, release

the drain plug (2, Figure 28). Drain the excessive oil into a

suitable container.

NOTE:

Dispose of drained fluids according to local

regulations.

FG014362

Figure 28

OP000812

Inspection, Maintenance and Adjustment

4-19

Clean Dust Net in Front of Oil Cooler and

Intercooler

IMPORTANT

If running excavator in dusty area, check

dust net

everyday and clean it if dirty.

Lock

FG001984

Figure 29

Reverse

WARNING

Rotating

If using compressed air or water to clean the dust net, make

sure that proper eye protection is worn.

FG001794

Figure 30

WARNING

There should be no person in front of the fan in order to

keep persons from being injured by scatterd material.

Open rear left door and engine cover.

Lock safety lever by rotating lever downward.

Turn "ON" the reverse fan switch.

FG001533

Reset fan switch after running fan for about three - five

Figure 31

minutes in reverse and turn "OFF" the fan switch.

Check the radiator grille contamination condition. If it is still

severely contaminated, loosen wing bolt(s) and remove

dust net.

Use compressed air or water to clean the core.

WARNING

If using compressed air or water to clean the dust net,

make sure that proper eye protection is worn.

Inspection, Maintenance and Adjustment

OP000812

4-20

Check Cooling System and Refill As

Required

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 performed.

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

NOTE:

Do not mix ethylene glycol and propylene glycol

antifreeze together. If the two are mixed, the

protection level will be reduced to the level of the

ethylene glycol.

When the engine is cold, remove the radiator cap and

check the coolant level inside the radiator. Do not rely on

the level of coolant in the coolant recovery tank. Refill

radiator as required. Refer to coolant concentration table.

(See page 4-82)

Check to make sure that the coolant transfer line from the

coolant recovery tank to the radiator is free and clear of

obstructions, or not pinched.

Observe the level of coolant in the coolant recovery tank.

The normal cold engine fluid level should be between

FG001534

"FULL" and "LOW" marks on tank.

Figure 32

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

tank.

Check Level of Window Washer Liquid

Open left front access door and check fluid level in

windshield washer tank.

Open fill cap and add fluid.

NOTE:

Use a washer liquid that is rated for all seasons.

This will prevent freezing during cold weather

operation.

FG000295

Figure 33

OP000812

Inspection, Maintenance and Adjustment

4-21

Inspect the Bucket Teeth and Side Cutters

for Signs of Wear

On a daily basis, inspect the bucket teeth to make sure that

tooth wear or breakage has not developed.

Do not allow the replaceable bucket teeth to wear down to

the point that the bucket adapter is exposed. See Figure

34.

NOTE:

These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers'

buckets, refer to their specific instructions.

Figure 34 1. POINT, 2. ADAPTER and 3.

Inspect Engine Fan Blade

WARNING

Personal injury can result from a fan blade failure. Never

pull or pry on the fan. This can damage the fan blade(s) and

cause fan failure.

NOTE:

Manually rotate the crankshaft by using a wrench on

the accessory drive pulley nut.

Figure 35

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

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

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

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

necessary. Replace any fan that is damage.

Inspection, Maintenance and Adjustment

OP000812

4-22

Check Air Intake System

CAUTION

Hot engine components can cause burns.

Avoid contact with hot engine components

Park the machine on a level surface, lower the attachment

to the ground, set safety lever to "LOCK" position, and shut

HAOA050L

down engine.

Figure 36

Check the engine intake hose, and hose bands for damage

and tightness.

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

contact your nearest DOOSAN dealer.

IMPORTANT

Severe engine damage will result from running with

unfiltered air.

Do not operate engine if any leaks or defects are found on

FG001539

air intake system.

Figure 37

Inspect Seat Belt for Proper Operation

Inspect the Structure for Cracks and

Faulty Welds

During the daily walk-around inspection and when

greasing the machine, look for any visible damage to the

machine. Repair or replace any damaged parts before

operating the machine.

Check the Operation of All Switches

Verify the working condition of all switches before starting

the engine.

OP000812

Inspection, Maintenance and Adjustment

4-23

Check the Operation of All Exterior Lights,

Horn and Control Console Indicator

and Monitor Lights

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

observe all of the indicator lights.

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

at this time.

Sound the horn. Repair or replace if required.

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

monitors, burned out bulbs or cracked or broken housings

or lenses.

Start Engine, Check Starting Ability, and

Observe Exhaust Color at Start-up and

at Normal Operating Temperature.

Listen for Any Abnormal Sounds

Check Operation of All Controls

IMPORTANT

Cold weather operation requires that the operator fully

warm up the hydraulic oil before beginning machine

operation. Follow all warm up instructions listed in the

Operating Instruction section of this manual. Make sure to

cycle oil through all of the components, including all

cylinders, both travel motors and the swing motor. Cold

hydraulic oil in the lines and components needs to be

warmed before beginning full operation. If this is not done,

damage to the cylinders or hydraulic motors can occur.

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

Follow cold weather hydraulic system warm-up

procedures.

Note any slow operations or unusual movements.

Determine the cause and repair the fault before operating.

Inspection, Maintenance and Adjustment

OP000812

4-24

50 HOUR / WEEKLY SERVICE

Perform All Daily Service Checks

Grease Arm and Bucket Joint Pins

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

thereafter.

NOTE:

If the unit has been running or working in water the

front attachment should be greased on a 10 hour /

daily basis.

•

Position machine as shown below and lower the front

attachment to the ground and shut down engine

•

Press the grease fitting and inject grease with the

grease gun on the marked point

•

After injection, clean off the old grease that has been

purged.

B,E

FG001437

Figure 38

Reference

Description

Number

Arm Link Joint Pin (1 Point)

Bucket Link Joint Pin (1 Point)

Link Joint Pin (2 Points)

Bucket Cylinder Rod Pin (1 Point)

Arm Bucket Joint Pin (1 Point)

OP000812

Inspection, Maintenance and Adjustment

4-25

Arm link joint pin (1 point)

Link joint pin (2 points)

Arm bucket joint pin (1 point)

Bucket link joint pin (1 point)

FG001538

Figure 39

Bucket cylinder rod pin (1 point)

FG001439

Figure 40

Grease Swing Bearing

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

attachment to the ground and shut down engine.

There are three grease fittings for the swing bearing. Do

not over lubricate. Purge old grease with new. Remove all

purged grease.

FG001541

Figure 41

Inspection, Maintenance and Adjustment

OP000812

4-26

Drain Water and Sediment from Fuel Tank

Perform this procedure before operating the machine.

Drain water and sediment from bottom of fuel tank into a

suitable container.

NOTE:

Dispose of drained fluid according to local

regulations.

NOTE:

Always completely fill fuel tank at end of each

workday to prevent condensation from forming

on the inside walls of the tank.

FG000296

Figure 42

Check Engine Fan Belt for Cracks, Wear

and Correct Tension (After First 50

Hours)

Inspect after first 50 hours of operation and every 250

hours thereafter. For details, See “Check Engine Fan Belt

Tension” on page 4-30.

Change Engine Oil and Filter (After First 50

Hours)

Change engine oil and filter after first 50 hours of operation

or rebuild, then every 500 thereafter. For details, See

“Change Engine Oil and Filter” on page 4-35.

Inspect the Track Assemblies for Proper

Tension and Loose, Worn or Damaged

Parts (Links, Shoes, Rollers, Idlers)

Do a daily walk-around inspection of all components

including the track assemblies. Look for missing, damaged

or excessively worn parts. See “Track Tension” on

page 4-86.

Jack up each track and perform the two speed travel motor

test.

OP000812

Inspection, Maintenance and Adjustment

4-27

250 HOUR / MONTHLY SERVICE

Perform All Daily and 50 Hour Service

Checks

Grease Boom and Arm Joint Pins

Grease every 10 hours for first 100 hours and every 250 hours

thereafter.

NOTE:

If the unit has been running or working in water the

front attachment should be greased on a 10 hour /

daily basis.

•

Position machine as shown below and lower the front

attachment to the ground and shut down engine

•

Press the grease fitting and inject grease with the

grease gun on the marked point

•

After injection, clean off the old grease that has been

purged.

B,C,D

FG001440

Figure 43

Reference

Description

Number

Boom Cylinder Head Pin (2 Points)

Boom Arm Joint Pin (2 Points)

Boom Foot Pin (2 Points)

Arm Cylinder Rod Pin (1 Point)

Boom Cylinder Rod Pin (2 Points)

Bucket Cylinder Head Pin (1 Point)

Arm Cylinder Head Pin (1 Point)

Inspection, Maintenance and Adjustment

OP000812

4-28

Check Engine Fan Belt Tension

ALTERNATOR

IMPORTANT

A loose fan belt can cause engine overheating, poor

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

COMPRESSOR

can cause damage to the water pump, alternator bearing or

WATER

belt.

PUMP

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

operation.)

CRS Pulley

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

FG001755

by pressing downwards on the belt, midway between the

Figure 47

fan pulley and alternator pulley. The belt should flex

approximately 10 mm (0.4 in). See Figure 47. To adjust the

belt, loosen the alternator adjustment plate bolts, adjust the

belt tension and retighten the bolts.

Inspection, Maintenance and Adjustment

OP000812

4-30

Check Engine Fan Belt Wear

WARNING

Keep clear of engine fan and fan drive belts when the

engine is running. Rotating fan and belt contact can cause

injury.

Figure 48

WARNING

When checking, adjusting or replacing drive belts, care

must be taken to prevent accidental cranking of the engine.

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

controls are tagged.

Replace badly worn, greasy or severely cracked belts

immediately. These conditions prevent proper belt

function. Visually inspect the belt. Check the belt for

intersecting cracks. Transverse (across the belt width)

cracks are acceptable. Longitudinal (direction of belt

length) cracks that intersect with transverse cracks are not

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

material missing.

Before installing new belts, make sure all pulley grooves

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

the grooves are worn.

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

working order.

When replacing belts and pulleys, pulley alignment must

be checked with belts tensioned and brackets securely

clamped. A misalignment that can be detected by the

naked eye is detrimental to belt performance.

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

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

cords which will cause the belts to turn and result in

complete destruction of the belts in operation.

Belts on new machines and replacement belts lose their

tension as they seat into the pulley grooves. Check the

tension of new belts at 50 hour intervals until tension is

stabilized and thereafter, every 250 hours. If the tension

falls below the required minimum, the belt slips damaging

the belts and pulley grooves.

NOTE:

When operating in abrasive conditions, check

tension every 100 hours.

OP000812

Inspection, Maintenance and Adjustment

4-31

Check Oil Level in Travel Reduction

Device (One on Each Side of Unit)

WARNING

The gear oil is very hot after the machine has been operating.

Shut all systems down and allow them to cool. Before fully

removing any motor case inspection port plug, etc., loosen

the plug slightly to allow pressurized air to escape.

FG001547

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

Figure 49

Rotate the track until ports (1 thru 3, Figure 49) are in their

proper positions as shown.

Loosen fill plug (3, Figure 49) slightly to allow pressurized

air to escape.

Remove oil level plug (1, Figure 49).

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

level plug opening.

Add oil through the fill plug (3, Figure 49) opening, if

necessary.

Clean and install oil level and fill plugs (1 and 3, Figure 49).

Repeat this procedure on the other travel reduction device.

Change Breaker Filter Element (Optional)

WARNING

The hydraulic oil will be hot after normal machine operation.

Allow the system to cool down before changing pilot filter.

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

attachment to the ground and shut down engine.

FG001548

Loosen the hydraulic oil tank breather cap to release

Figure 50

pressure.

Locate breaker filter assembly (Figure 50).

Position a container under the filter assembly. Remove the

drain plug and completely drain the assembly.

Using a 30 mm spanner, unscrew filter housing from filter

bottom.

Remove O-ring from filter head.

Replace filter.

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

install the filter housing on the filter head.

NOTE:

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

Install drain plug in bottom of filter housing.

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

level of hydraulic oil tank.

Inspection, Maintenance and Adjustment

OP000812

4-32

Change Swing Reduction Device Oil (Drain

and Refill After First 250 Hours)

NOTE:

Change swing reduction device oil after first

250

hours on a new machine and every 2,000 hours

thereafter (See page 4-49).

Change Oil in Travel Reduction Device

(One on Each Side of Unit) (After First

250 Hours)

NOTE:

Drain and refill oil after first 250 hours of operation or

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

4-46).

Replace Hydraulic Oil Return Filter (After

First 250 Hours)

NOTE:

Replace hydraulic oil return filter after first 250 hours

of operation or rebuild, then every

1,000 hours

thereafter (See page 4-44).

Change Pilot Filter (After First 250 Hours)

NOTE:

Change pilot filter after first 250 hours and every

1000 hours thereafter (See page 4-45).

Inspect Pins and Bushings of the Front

End Attachments for Signs of Wear

Check Fluid Levels in Batteries and

Battery Charge Levels

Inspect for Any Loose or Missing Nuts and

Bolts

Inspect Fuel System Hose Clamps

OP000812

Inspection, Maintenance and Adjustment

4-33

500 HOUR / 3 MONTH SERVICE

Perform All Daily, 50 and 250 Hour Service

Checks

Grease Swing Gear and Pinion

WARNING

Greasing swing gear and pinion must be serviced by only

one person.

Remove inspection cover and inspect the condition of the

grease. Make sure that water or other contaminants are

not noticeable.

NOTE:

The upper structure must be rotated a little at a

time so that the entire face of the swing gear

can be lubricated. Use extreme caution when

performing this operation.

FG001549

Figure 51

If water or other contaminations are found, remove the

lower access cover so that the gear teeth can be

thoroughly cleaned and lubricated.

Install access covers after lubricating gear teeth.

FG000148

Figure 52

Inspection, Maintenance and Adjustment

OP000812

4-34

Change Engine Oil and Filter

NOTE:

Change engine oil and filter after first 50 hours of

operation or rebuild, then every 500 thereafter.

WARNING

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

cool down before attempting to change the engine oil and

filter to avoid burns by touching hot engine parts.

Position a larger container under the engine. Remove cap

(1, Figure 53) and install hose (2) to drain the engine oil.

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

NOTE:

Dispose of drained fluids according to local

regulations.

FG001550

Figure 53

Replace engine oil filter by using filter wrench. The engine

oil filter is a spin-on type. See Figure 54. Remove and

discard filter.

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

gasket. Screw filter on head until gasket contacts head,

turn filter 1/2 turn more.

FG001551

Figure 54

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

(Figure 55). Refer to the Lubrication Table of this manual

for the recommended oil for the operating conditions.

NOTE:

See “Fluid Capacities” on page 4-8. for

capacity.

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

and check engine oil pressure light.

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

oil level after fifteen minutes.

FG001552

Figure 55

OP000812

Inspection, Maintenance and Adjustment

4-35

Clean Air-Conditioning Outer Filter

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

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

cabin. This filter should be cleaned out.

NOTE:

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

environment, the cleaning and replacement should

be performed more frequently. If filter is damaged,

replace damaged filter with a new one.

WARNING

All service and inspection of air-conditioning system

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

(OFF) position.

WARNING

If using compressed air to clean the element, make sure

that proper eye protection is worn.

Donaldson.

NOTE:

All right and left call outs are based on the operator

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

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

the cover (1, Figure 56) by loosening the four wing bolts.

FG000440

Figure 56

Open the cover by turning the knob (1, Figure 57) in the

rear of the cabin.

FG000441

Figure 57

Remove filter (Figure 58) and inspect for any damage.

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

change to new one.

Reassemble in reverse order.

FG000342

Figure 58

Inspection, Maintenance and Adjustment

OP000812

4-36

Check and Clean Air-Conditioning Inner

Filter

WARNING

All service and inspection of air-conditioning system

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

(OFF) position.

WARNING

FG000422

If using compressed air to clean the element, make sure

Figure 59

that proper eye protection is worn.

Remove the filter by pulling out ward the knob while

pressing the upper part and lower part of the filter handle

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

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

damaged replaced by a new one.

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

water to clean it.

IMPORTANT

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

completely dry before installing.

OP000812

Inspection, Maintenance and Adjustment

4-37

Clean Radiator, Oil Cooler, Intercooler,

Fuel Cooler and Air Conditioner

Condenser Core

WARNING

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

there is danger of injury. Always wear protective glasses,

FG001553

mask and safety shoes during the cleaning precess. Make

Figure 60

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

Open the rear left door and engine cover.

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

of oil cooler and intercooler.

Clean the outside of the radiator and oil cooler, intercooler

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

from the outside of the engine compartment inwards.

Repeat the cleaning process from the inside of the engine

compartment outwards to remove all dirt and debris.

NOTE:

Clean dust net and install it after cleaning

radiator, oil cooler, intercooler and fuel cooler.

FG001533

Figure 61

Clean air conditioner condenser core with compressed air,

steam or water.

IMPORTANT

To prevent damage to the cores, apply compressed air

from an appropriated distance. Damaged core may

cause water leakage or overheating. In a dusty site,

check the core daily, irrespective of the maintenance

interval.

FG001562

Figure 62

Inspection, Maintenance and Adjustment

OP000812

4-38

Clean Outer Filter of Air Cleaner

NOTE:

Clean outer filter every 500 hours / 3 months of

service.

NOTE:

If air cleaner clogged warning light (Figure 63)

on instrument panel comes "ON" the air cleaner

must be serviced.

NOTE:

When working in severely dusty conditions, the

PWR

service interval should be shortened.

FG013734

Figure 63

WARNING

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

engine is running.

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

proper eye protection is worn.

Locate the air cleaner assembly.

NOTE:

When it reaches every 500 hours or If indicator

light (Figure 63) on instrument panel comes

"ON" the air cleaner must be serviced.

NOTE:

Replace outer filter after cleaning 5 times or

every 2,000 hours / 1 year of service.

Remove and clean rubber evacuator valve (1, Figure 64)

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

lips for wear or damage. Replace valve if necessary.

FG000297

NOTE:

Install evacuator valve with lips parallel to the

Figure 64

cover.

Remove the access cover (2, Figure 65) by loosening the

latches (3).

Remove the outer filter (4, Figure 65) from the housing. Do

not remove inner filter (5).

FG000702

Figure 65

OP000812

Inspection, Maintenance and Adjustment

4-39

Clean the outer filter (4, Figure 65) by blowing compressed

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

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

HAOC570L

Figure 66

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 67

outer and inner filters. Do not clean inner filter.

Inspection, Maintenance and Adjustment

OP000812

4-40

Change of Fuel Prefilter

Open the left rear side door to access fuel prefilter.

Position a small container under prefilter. Drain fuel by

opening drain valve on bottom of filter.

NOTE:

Dispose of drained fluids according to local

regulations.

FG001554

Figure 68

Remove the bowl using supplied tool.

Remove the cartridge.

FG001561

Figure 69

Coat surface of packing (2, Figure 70) with fuel on new

cartridge (1).

Tighten the cartridge by hand until the packing comes into

contact with the surface of the filter housing head.

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

of a turn more.

Coat surface of seal (3, Figure 70) with fuel, and tighten

the bowl with tool.

FG000428

Figure 70

OP000812

Inspection, Maintenance and Adjustment

4-41

Change Fuel Filter

WARNING

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

fire hazards. Do not smoke.

Locate fuel filter inside engine compartment.

FG001563

Position a small container under fuel filter.

Figure 71

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 72

Fuel System Priming

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

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

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

engine speeds.

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

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

procedure:

Shut down engine.

FG000431

Loosen plug (1, Figure 73) on the fuel prefilter head.

Figure 73

Pump the hand operated primer pump (2, Figure 73) on the

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

in fuel prefilter head.

Tighten plug (1, Figure 73) in fuel prefilter head.

Continue to pump primer pump until a strong resistance is

felt.

Start engine and look for signs of leaks.

Repeat procedure if necessary.

Inspection, Maintenance and Adjustment

OP000812

4-42

1,000 HOUR / 6 MONTH SERVICE

Perform All Daily, 50, 250 and 500 Hour

Service Checks

Grease Swing Reduction Device

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

attachment to the ground and shut down engine.

Remove air vent plug (1, Figure 74) from swing reduction

device.

FG001564

Figure 74

Press grease fitting and inject grease with the grease gun

on the marked point (2, Figure 75).

Install air vent plug (1, Figure 74) in swing reduction

device.

FG001565

Figure 75

OP000812

Inspection, Maintenance and Adjustment

4-43

Replace Hydraulic Oil Return Filter

NOTE:

Change hydraulic oil return filter after first 250 hours

of operation or rebuild, and every

1,000 hours

thereafter.

NOTE:

If return filter clogged warning light (Figure 76) on

instrument panel comes "ON" the return filter must be

serviced.

FG013832

Figure 76

WARNING

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool before attempting to

service any of the hydraulic components.

The hydraulic tank is pressurized. Lift the hydraulic

breather cap slightly to allow the pressurized air to vent.

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

FG001566

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

tank.

Figure 77

IMPORTANT

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

hydraulic tank, especially around the fill port and filter

ports.

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

attachment to the ground and shut down engine.

Lift the breather cap (1, Figure 77) slightly to release the

internal pressure.

Remove bolts

(2, Figure

77) and service cover

(3).

Remove spring (4), valve (5) O-ring (6), and bypass

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

Remove filter and discard.

NOTE:

Used filter should always be disposed of

according to local regulations.

FG000761

Figure 78

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

valve and spring. Install service cover plate.

Tighten the breather cap (1, Figure 77).

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

circuit.

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

necessary.

Inspection, Maintenance and Adjustment

OP000812

4-44

Change Pilot Filter

NOTE:

Change pilot filter after first 250 hours of operation or

rebuild, and every 1,000 hours thereafter.

NOTE:

If pilot filter clogged warning light (Figure 79) on

instrument panel comes "ON" the pilot filter must be

serviced.

FG013895

Figure 79

WARNING

The hydraulic oil will be hot after normal machine

operation.

Allow the system to cool down before changing pilot filter.

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

attachment to the ground and shut down engine.

FG001567

Lift the breather cap (1, Figure 77) slightly to release the

Figure 80

internal pressure.

Locate pilot system filter assembly. See Figure 80.

Unscrew canister (5, Figure 81) and remove O-ring (3) and

filter cartridge (4).

NOTE:

The canister will be filled with oil. Use caution

when removing this assembly.

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

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

canister assembly onto the filter head (1, Figure 81).

NOTE:

Used filter should always be disposed of

according to local regulations.

FG000323

After changing pilot filter, vent air from pump and check

Figure 81

level of hydraulic oil tank.

OP000812

Inspection, Maintenance and Adjustment

4-45

Change Oil in Travel Reduction Device

(One on Each Side of Unit)

WARNING

The gear oil is very hot after the machine has been

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

Before fully removing any motor case, inspection port plug,

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

FG001547

escape.

Figure 82

NOTE:

Drain oil after first 250 hours of operation or rebuild,

and every 1,000 hours thereafter.

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

Rotate the track until ports (1 thru 3, Figure 82) are in their

proper positions as shown.

Place a container under drain plug (2, Figure 82) and

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

oil.

NOTE:

Dispose of drained fluids according to local

regulations.

Install drain plug (2, Figure 82). Refill the travel reduction

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

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

NOTE:

See “Fluid Capacities” on page 4-8. for

capacity.

Repeat this procedure on the other travel reduction device.

Change Air Breather Filter

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

attachment to the ground and shut down engine.

Lift the breather cap(2. Figure 83) slightly to release the

internal pressure.

Unscrew the bolt (1, Figure 83) and take off the breather

cap (2, Figure 83).

Change a filter cartridge (3, Figure 83) and assemble the

breather cap by tighting the bolt.

NOTE:

Used filter should always be disposed of

according to local regulations.

FG013207

Figure 83

Inspection, Maintenance and Adjustment

OP000812

4-46

Change Air-Conditioning Outer Filter

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

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

cabin. This filter should be cleaned out.

NOTE:

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

environment, the cleaning and replacement should

be performed more frequently. If filter is damaged,

replace damaged filter with a new one.

WARNING

All service and inspection of air-conditioning system

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

Donaldson.

(OFF) position.

NOTE:

All right and left call outs are based on the operator

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

FG000440

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

Figure 84

four wing bolts and washers, and access cover (1, Figure 84).

Open the cover by unscrewing the knob (1, Figure 85) in

the rear of the cabin.

FG000441

Figure 85

Remove filter (Figure 86) and replace with new one.

Reassemble in reverse order.

FG000342

Figure 86

OP000812

Inspection, Maintenance and Adjustment

4-47

Check Air Conditioner Refrigerant

WARNING

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging

air-conditioning system.

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

FG001568

ten minutes to stabilize the system.

Figure 87

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

Put the temperature control switch in maximum cooling

position.

Press the "Internal Air Circulation" switch.

Compare the flow of bubbles in the sight glass of receiver

dryer with the drawings in the following table.

CAUTION

Overfilling refrigerant may cause dangerous

high-pressure and poor cooling action; and low

refrigerant level may cause compressor damage.

Always maintain refrigerant at normal level.

Amount of

Appearance of the Sight Glass

Solutions

Refrigerant

Almost clear.

Normal

Any bubbles disappear.

Charge or withdraw the system with

the correct amount of HFC-134a

High

No bubbles are seen.

refrigerant.

Low

A flow of bubbles is visible.

Check and Adjust Engine **

Contact your nearest DOOSAN dealer.

Engine dealer for checking and adjusting the following items:

•

Engine Compression Pressure.

•

Injection Pressure.

•

Injection Timing.

Inspection, Maintenance and Adjustment

OP000812

4-48

2,000 HOUR / YEARLY SERVICE

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

Hour Service Checks

Change Swing Reduction Device Oil

NOTE:

Change swing reduction device oil after first

250

hours of operation or rebuild and every 2,000 hours

thereafter.

WARNING

The gear oil is very hot after the machine has been

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

FG001520

Figure 88

Set a container under excavator.

Release the drain plug (3, Figure 89) and drain the swing

reduction device oil into a container.

NOTE:

Dispose of drained fluids according to local

regulations.

After draining oil, tighten the drain plug.

FG014362

Figure 89

Remove breather/fill cap (2, Figure 88) and add oil to "H"

mark on dipstick (1).

FG000419

Figure 90

OP000812

Inspection, Maintenance and Adjustment

4-49

Replace Outer and Inner Air Cleaner

Elements

WARNING

Never clean or attempt to remove the air cleaner element if

the engine is running.

NOTE:

Replace outer element after cleaning 5 times or every

FG000414

2,000 hours of service.

Figure 91

NOTE:

Replace inner element whenever a new outer

element is installed.

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

following procedure.

Open the access door at the rear of the cabin.

Remove the evacuator valve (1, Figure 92) and air cleaner

cover (2).

NOTE:

Inspect evacuator valve seal lips for wear or

damage. Replace valve if necessary. Install

FG000425

evacuator valve with lips parallel to the cover.

Figure 92

Remove outer filter (4, Figure 92) from the air cleaner

housing.

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

housing.

Remove inner filter (5, Figure 93).

Clean out inside of air cleaner housing. Do not use

compressed air to blow out housing.

Install new inner filter. Do not clean and reuse inner

element.

Install new outer filter.

Install air cleaner cover and evacuator valve.

NOTE:

Make sure that all gaskets and cover are

properly installed and seated.

FG000426

Figure 93

Inspection, Maintenance and Adjustment

OP000812

4-50

Change Radiator Coolant

WARNING

Allow the engine to cool before releasing the radiator cap.

Make sure to loosen the cap slowly to release any

remaining pressure.

Radiator cleaning is performed while the engine is running.

Take extreme caution when working on or near a running

ARO1760L

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

Figure 94

personnel that service work is being performed.

Do not remove the radiator cap unless it is required.

Observe the coolant level in the coolant recovery tank.

CAUTION

Do not mix ethylene glycol and propylene glycol when

changing the antifreeze solution. Flushing should be

performed to minimize volume of mixing between the two

columns. Mixing the two compounds may cause generation

of foreign material to damage the system.

Do not mix antifreeze solutions from different

manufactures. Mixed solution may degrade the capabilities

of the system. It is recommended to use the standard

product from Doosan.

In the bitterly cold area or weather, the customer should

frequently check the performance of the coolant for

appropriateness for the weather, and then determine

change cycle of the coolant.

Slowly open the radiator cap to allow any pressure to

escape.

Place a container under the radiator and open the drain

valve (2, Figure 95).

NOTE:

Dispose of drained fluids according to local

regulations.

FG001569

Figure 95

OP000812

Inspection, Maintenance and Adjustment

4-51

Remove coolant drain plug (1, Figure 96) from engine.

Install drain plug, and close drain valve after coolant has

completely drained from system.

Fill cooling system with a flushing solution.

Run engine at low idle until the coolant temperature gauge

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

minutes.

Allow engine to cool.

Drain flushing fluid and fill system with water.

FG001572

Figure 96

Run engine again to allow water to completely circulate.

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

with proper antifreeze mixture for ambient temperature.

Refer to coolant concentration table. See “Antifreeze

Concentration Tables” on page 4-82.

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

be purged from system. Fill radiator to fill neck.

12. Drain and fill radiator coolant recovery tank.

Hydraulic Oil Exchange and Suction

Strainer Cleaning

WARNING

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool before attempting to

service any of the hydraulic components.

ARO1760L

The hydraulic tank is pressurized. Lift the breather cap to

Figure 97

allow the pressurized air to vent. After the pressure has

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

service covers.

IMPORTANT

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

hydraulic tank, especially around the fill port and filter ports.

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

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

used, guaranteed change interval is 1,000 hours.

NOTE:

Based on the type of excavating being completed,

the working conditions (extremely hot or dusty) and

the extra front end attachments being used (hydraulic

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

changed more frequently.

Inspection, Maintenance and Adjustment

OP000812

4-52

Position the machine on firm, level ground. Swing upper

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

position bucket on ground as shown in Figure 98.

Set safety lever on "LOCK" position.

Shut down engine.

Release pressurized air from hydraulic tank by lifting

breather cap (1, Figure 101).

FG000356

Figure 98

Drain hydraulic oil from tank into a container capable of

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

drain plug.

IMPORTANT

Be careful of squirting oil when removing drain plug.

NOTE:

Used filter and used oil should always be

disposed of according to local regulations.

FG014361

Figure 99

Carefully remove bolts and cover (2, Figure 101) from top

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

that will force the cover up.

Remove spring (3, Figure 101) and strainer (5), by pulling

on rod (4).

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

broken.

Position strainer (5, Figure 101) on boss portion of suction

pipe (6).

NOTE:

Measurement "A" is 606.5 mm (23.88 in).

HAOC411L

Figure 100

OP000812

Inspection, Maintenance and Adjustment

4-53

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

side of tank.

11. Place spring (3, Figure 101) on rod (4) and assemble cover

(2).

12. After replacing and cleaning the hydraulic oil, filter and

strainer, vent the system. See “Venting and Priming

Hydraulic System” on page 4-88.

IMPORTANT

When the hydraulic breaker is being used, due to the

higher heat generated by this unit, use replacement

intervals recommended under the “Hydraulic Oil and

Filter Service Intervals” on page 3-36.

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

ARO1720L

Figure 101

Check Alternator and Starter**

**These checks need to be completed by an authorized

DOOSAN dealer.

Check All Rubber Antivibration Shock

Mounts

Perform and Record the Results of the

Cycle Time Tests

Inspect Machine to Check for Cracked or

Broken Welds or other Structural

Damage

Check, Adjust Valve Clearance **

Check Head Bolt Torques

Inspection, Maintenance and Adjustment

OP000812

4-54

4,000 HOUR / BIENNIAL

SERVICE

Major Parts - Periodic Replacement

To ensure safe operation and work, perform periodic

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

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

and fatigue. Exchange these parts with new ones at the

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

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

Use only original equipment manufacturers parts.

Major Component

Parts Name to be Exchanged Periodically

Time to Exchange

Engine

Fuel hose (Tank to fuel prefilter)

Fuel hose (Fuel prefilter to fuel cooler)

Fuel hose (Fuel cooler to ECU)

Fuel hose (ECU to engine CP pump)

Fuel hose (Tank to CP pump)

Heater hose (Heater to engine)

Heater hose (Heater to radiator)

Air Conditioner hose

2 years or 4,000 hours

Hydraulic

Body

Pump suction hose

System

Pump discharge hoses

Pump side branch hoses

Swing motor hoses

Travel motor hoses

Work

Boom cylinder line hoses

Device

Arm cylinder line hoses

Bucket cylinder line hoses

OP000812

Inspection, Maintenance and Adjustment

4-55

12,000 HOUR / 6 YEAR SERVICE

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)

European regulations state that the in-service life of any

hydraulic hose may not exceed six years. DOOSAN

recommends the following;

•

Hoses at the customer premises cannot be stored

more than 2 years before being discarded or installed

on a machine.

•

In-service lifetime of hoses fitted on a machine can

never exceed 6 years, but replace hoses described in

“Major Parts - Periodic Replacement” on page 4-55,

every

2 years. Always replace hoses having

exceeded the allowed in-service lifetime irrespective

of the external appearance/wear.

•

Always store hoses in a dark place at a maximum of

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

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

away from copper, manganese or tube generating

Ozone.

Inspection, Maintenance and Adjustment

OP000812

4-56

REMOVABLE COUNTERWEIGHT

LINKAGE LUBRICATION

(OPTIONAL)

NOTE:

Any time that removable counterweight is removed or

installed, the following grease fitting must be

lubricated.

Removal Cylinder Head Pin (2 points)

FG012313

Figure 102

Removal Cylinder Rod Pin (2 points)

Lifting Arm Support Pivot Pin (2 points)

Push Link Push Link Pivot Pin (2 points)

Lifting Arm Push Link Pivot Pin (2 points)

FG012314

Figure 103

Push Link Support Pivot Pin (2 points)

FG012315

Figure 104

OP000812

Inspection, Maintenance and Adjustment

4-57

AIR-CONDITIONING SYSTEM

NOTE:

See “Clean Air-Conditioning Outer Filter” on

page 4-36.

Check Control Panel

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

displayed on the LCD display.

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

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

Check Air Conditioner Hoses

Check the hose for cracking and damage.

CAUTION

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

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

Check Condenser

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

NOTE:

See “Clean Radiator, Oil Cooler, Intercooler, Fuel

Cooler and Air Conditioner Condenser Core” on

page 4-38.

Check Magnetic Clutch

Check the magnetic clutch for dirt and interference.

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

check the magnetic clutch.

Check Belt Tension

NOTE:

See “Check Engine Fan Belt Tension” on page 4-30.

Inspection, Maintenance and Adjustment

OP000812

4-58

BOLT AND NUT INSPECTION

Inspect ALL fasteners after the first 50 hours of operation and

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

tighten them or install new hardware. Always use a calibrated

torque wrench.

IMPORTANT

Always clean fasteners before tightening.

If counterweight is loose, contact a DOOSAN distributor or

sales agent.

BOLT

TORQUE

NO.

POINT TO BE INSPECTED

DIA.

QTY.

HEAD

kg•m

ft lb

SIZE

Joint bolt with engine

pump side

205

152

mounting bracket and

fan side

12/14

4/4

19/22

10.5/17

103/167

76/123

engine

Joint bolt and nut

pump side

451

333

between engine mount-

fan side

451

333

ing bracket and frame

Radiator mounting bolt

265

195

Tightening bolt for hydraulic oil tank

265

195

Tightening bolt for fuel tank

265

195

Tightening bolt for pump

4/8

11/9

108/88

80/65

Tightening bolt for control valve

539

398

Tightening bolt for swing reduction device

539

398

Tightening bolt for swing motor

14.4

141

104

Tightening bolt for battery

Joint bolt with cabin mounting rubber and

6.5

frame

Joint bolt with cabin mounting rubber and

206

152

cabin

Joint bolt with swing bearing and upper

931

687

frame

Joint bolt with swing bearing and bottom

931

687

frame

Tightening bolt for travel device

585

433

Tightening bolt for sprocket

585

433

Tightening bolt for upper roller (Inner

735

542

flange)

Tightening bolt for upper roller (Outer

265

195

flange)

Tightening bolt for bottom roller

735

542

Tightening bolt for track guard

735

542

Bolt for track shoes

424

105

1029

759

OP000812

Inspection, Maintenance and Adjustment

4-59

BOLT

TORQUE

NO.

POINT TO BE INSPECTED

DIA.

QTY.

HEAD

kg•m

ft lb

SIZE

Fixing bolt for front pin

265

195

Fixing bolt for front pin (a)

392

289

Fixing bolt for front pin (b)

490

362

Fixing bolt for track frame and side frame

175

1715

1265

Fixing bolt for fan motor

108

Fixing bolt for auxiliary pump

108

Breaker Filter (Optional)

265

195

Fixing bolt for main frame and RCW

931

687

support (Optional)

Fixing bolt for RCW cylinder pin (a)

108

(Optional)

Fixing bolt for RCW cylinder pin (b)

108

(Optional)

Fixing bolt for RCW link pin (a) (Optional)

108

Fixing bolt for RCW link pin (b) (Optional)

108

Inspection, Maintenance and Adjustment

OP000812

4-60

Joint bolt with engine mounting bracket and engine

1) Pump side

•

Tool: 24 mm (

)

•

Torque: 21 kg•m (205 Nm, 152 ft lb)

FG001581

Figure 105

2) Fan side

- Top (1)

•

Tool: 19 mm (

)

•

Torque: 10.5 kg•m (103 Nm, 76 ft lb)

- Bottom (2)

•

Tool: 22 mm (

)

•

Torque: 17 kg•m (167 Nm, 123 ft lb)

FG001582

Figure 106

Joint bolt and nut between engine mounting bracket and

frame

1) Pump side

•

Tool: 30 mm (

)

•

Torque: 46 kg•m (451 Nm, 333 ft lb)

FG001583

Figure 107

2) Fan side

•

Tool: 30 mm (

)

•

Torque: 46 kg•m (451 Nm, 333 ft lb)

FG001584

Figure 108

OP000812

Inspection, Maintenance and Adjustment

4-61

Radiator mounting bolt

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG001585

Figure 109

Tightening bolt for hydraulic oil tank

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG001586

Figure 110

Tightening bolt for fuel tank

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG001587

Figure 111

Tightening bolt for pump

•

Tool: 19 mm (

)

•

Torque: 11 kg•m (108 Nm, 80 ft lb)

FG001588

Figure 112

Inspection, Maintenance and Adjustment

OP000812

4-62

Tightening bolt for control valve

•

Tool: 30 mm (

)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG001589

Figure 113

Tightening bolt for swing reduction device

•

Tool: 30 mm (

)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG001590

Figure 114

Tightening bolt for swing motor

•

Tool: 10 mm (

)

•

Torque: 14.4 kg•m (141 Nm, 104 ft lb)

FG001591

Figure 115

10. Tightening bolt for battery

•

Tool: 17 mm (

)

•

Torque: 5 kg•m (49 Nm, 36 ft lb)

FG001592

Figure 116

OP000812

Inspection, Maintenance and Adjustment

4-63

11. Joint bolt with cabin mounting rubber and frame

•

Tool: 17 mm (

)

•

Torque: 6.5 kg•m (64 Nm, 47 ft lb)

FG000454

Figure 117

Joint bolt with cabin mounting rubber and cabin

•

Tool: 24 mm (

)

•

Torque: 21 kg•m (206 Nm, 152 ft lb)

FG000455

Figure 118

12. Joint bolt with swing bearing and upper frame

•

Tool: 36 mm (

)

•

Torque: 95 kg•m (931 Nm, 687 ft lb)

FG001593

Figure 119

Joint bolt with swing bearing and bottom frame

•

Tool: 36 mm (

)

•

Torque: 95 kg•m (931 Nm, 687 ft lb)

FG001594

Figure 120

Inspection, Maintenance and Adjustment

OP000812

4-64

13. Tightening bolt for travel device

•

Tool: 30 mm (

)

•

Torque: 60 kg•m (585 Nm, 433 ft lb)

FG001595

Figure 121

Tightening bolt for sprocket

•

Tool: 30 mm (

)

•

Torque: 60 kg•m (585 Nm, 433 ft lb)

FG001596

Figure 122

14. Tightening bolt for upper roller

1) Outer flange

•

Tool: 32 mm (

)

•

Torque: 75 kg•m (735 Nm, 542 ft lb)

FG001597

Figure 123

2) Inner flange

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG001598

Figure 124

OP000812

Inspection, Maintenance and Adjustment

4-65

Doosan DX480LC, DX520LC. Operation and Maintenance Manual (2009) - page 4