Doosan DX700LC. Operation and Maintenance Manual (2010)

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 33

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 air intake system.

FG016105

Figure 34

Inspect Seat Belt for Proper Operation

Inspect the Structure for Cracks and

Faulty Welds

During the daily walk-around inspection and when

greasing the machine, look for any visible damage to the

machine. Repair or replace any damaged parts before

operating the machine.

Check the Operation of All Switches

Verify the working condition of all switches before starting

the engine.

Inspection, Maintenance and Adjustment

OP001123

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

OP001123

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 pressed on "Auto

Greasing Manual Button" (Manual Operating Switch

of Auto Greasing Device) a 10 hour / daily basis.

•

Position machine as shown below and lower the front

attachment to the ground. (at the engine "ON")

•

Press the grease fitting and inject grease with the

grease gun on the marked point. Please check the

marked point of greasig.

•

After injection, clean off the old grease that has been

purged.

D B, E

FG015803

Figure 35

Reference

Description

Number

Arm Link Joint Pin (1 Point)

Bucket Link Joint Pin (1 Point)

Link Joint Pin (2 Points)

Bucket Cylinder Rod Pin (1 Point)

Arm Bucket Joint Pin (1 Point)

Inspection, Maintenance and Adjustment

OP001123

4-25

A. Arm link joint pin (1 point)

B. Link joint pin (2 points)

C. Arm bucket joint pin (1 point)

D. Bucket link joint pin (1 point)

E. Bucket cylinder rod pin (1 point)

FG016128

Figure 36

FG016129

Figure 37

Grease Swing Bearing (Only Manual

Greasing)

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.

FG016197

Figure 38

Inspection, Maintenance and Adjustment

OP001123

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.

FG016106

Figure 39

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 4-87.

Jack up each track and perform the two speed travel motor

test.

Inspection, Maintenance and Adjustment

OP001123

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 check the marked

point of greasing every 250 hours thereafter.

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

front attachment should be pressed on "Auto

Greasing Manual Button" (Manual Operating Switch

of Auto Greasing Device) a 10 hour / daily basis.

•

Position machine as shown below and lower the front

attachment to the ground. (at the engine "ON")

•

Press the grease fitting and inject grease with the

grease gun on the marked point. Please check the

marked point of greasig.

•

After injection, clean off the old grease that has been

purged.

B,C,D

FG015804

Figure 40

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

OP001123

4-28

Check Engine Fan Belt Tension

Alternator

IMPORTANT

Water

Pump

Idle Pulley

A loose fan belt can cause engine overheating, poor

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

can cause damage to the water pump, alternator bearing or

belt.

CRS

Compressor

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

Pulley

operation.)

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

by pressing downwards on the belt, midway between the

fan pulley and alternator pulley. The belt should flex

Water

Alternator

approximately 6 - 8 mm (0.24 - 0.31 in). See Figure 44. To

Pump

adjust the belt, loosen the alternator adjustment plate bolts,

adjust the belt tension and retighten the bolts.

CRS

6 - 8 mm (0.24 - 0.31 in)/

Pulley

10 kg (22 Ib)

FG016161

Figure 44

Inspection, Maintenance and Adjustment

OP001123

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.

FG016132

Figure 45

WARNING

When checking, adjusting or replacing drive belts, care

must be taken to prevent accidental cranking of the engine.

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

controls are tagged.

Replace badly worn, greasy or severely cracked belts

immediately. These conditions prevent proper belt

function. Visually inspect the belt. Check the belt for

intersecting cracks. Transverse

(across the belt width)

cracks are acceptable. Longitudinal

(direction of belt

length) cracks that intersect with transverse cracks are not

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

material missing.

Before installing new belts, make sure all pulley grooves

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

the grooves are worn.

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

working order.

When replacing belts and pulleys, pulley alignment must

be checked with belts tensioned and brackets securely

clamped. A misalignment that can be detected by the

naked eye is detrimental to belt performance.

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

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

cords which will cause the belts to turn and result in

complete destruction of the belts in operation.

Belts on new machines and replacement belts lose their

tension as they seat into the pulley grooves. Check the

tension of new belts at 50 hour intervals until tension is

stabilized and thereafter, every 250 hours. If the tension

falls below the required minimum, the belt slips damaging

the belts and pulley grooves.

NOTE: When operating in abrasive conditions, check

tension every 100 hours.

Inspection, Maintenance and Adjustment

OP001123

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.

FG016109

Figure 46

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

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

proper positions as shown.

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

air to escape.

Remove oil level plug (1, Figure 46).

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

level plug opening.

Add oil through the fill plug

(3, Figure

46) opening, if

necessary.

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

Repeat this procedure on the other travel reduction device.

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.

FG016133

Loosen the hydraulic oil tank breather cap to release

Figure 47

pressure.

Locate breaker filter assembly (Figure 47).

Position a container under the filter assembly. Remove the

drain plug and completely drain the assembly.

Using a 30 mm spanner, unscrew filter housing from filter

bottom.

Remove O-ring from filter head.

Replace filter.

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

install the filter housing on the filter head.

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

Install drain plug in bottom of filter housing.

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

level of hydraulic oil tank.

Inspection, Maintenance and Adjustment

OP001123

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 4-51).

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

Inspection, Maintenance and Adjustment

OP001123

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.

FG016177

Figure 48

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 49

Inspection, Maintenance and Adjustment

OP001123

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 50) 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.

FG016110

Figure 50

Replace engine oil filter by using filter wrench. The engine

oil filter is a spin-on type. See Figure 51. 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.

FG016111

Figure 51

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

(Figure 52). 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.

FG016112

Figure 52

Inspection, Maintenance and Adjustment

OP001123

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.

Cover

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 53) by loosening the four wing bolts.

FG016162

Figure 53

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

rear of the cabin.

FG000441

Figure 54

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

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

change to new one.

Reassemble in reverse order.

FG000342

Figure 55

Inspection, Maintenance and Adjustment

OP001123

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 56

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.

Inspection, Maintenance and Adjustment

OP001123

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,

mask and safety shoes during the cleaning precess. Make

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

FG016114

Open the rear left door and engine cover.

Figure 57

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.

Clean air conditioner condenser core with compressed air,

steam or water.

FG016102

Figure 58

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.

Inspection, Maintenance and Adjustment

OP001123

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 59)

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 59

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

59) 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 60)

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

lips for wear or damage. Replace valve if necessary.

FG016134

NOTE: Install evacuator valve with lips parallel to the

Figure 60

cover.

Remove the access cover (2, Figure 61) by loosening the

latches

Remove the outer filter (3, Figure 61) from the housing. Do

not remove inner filter (4).

FG016115

Figure 61

Inspection, Maintenance and Adjustment

OP001123

4-39

Clean the outer filter (3, Figure 61) 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 62

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 63

outer and inner filters. Do not clean inner filter.

Inspection, Maintenance and Adjustment

OP001123

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.

FG015800

Figure 64

Remove the bowl using supplied tool.

Remove the cartridge.

FG016116

Figure 65

Coat surface of packing (2, Figure 66) 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 66) with fuel, and tighten

the bowl with tool.

FG000428

Figure 66

Inspection, Maintenance and Adjustment

OP001123

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.

Position a small container under fuel filter.

FG016135

Figure 67

Unscrew fuel filter from head assembly. Discard fuel filter.

NOTE: Dispose of drained fluids according to local

regulations.

Change new O-ring in the filter cases.

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

on head until gasket contacts head, and turn filter 1/4 turn

more with a filter wrench.

NOTE: Coat fuel filter gasket with fuel.

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

FG016178

reduce fuel system priming.

Figure 68

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 69) on the fuel prefilter head.

Figure 69

Pump the hand operated primer pump (2, Figure 69) on the

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

in fuel prefilter head.

Tighten plug (1, Figure 69) 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

OP001123

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 70) from swing reduction

device. (at manual gerasing ports)

FG001564

Figure 70

Press grease fitting and inject grease with the grease gun

on the marked point (2, Figure 71).

Install air vent plug

(1, Figure

70) in swing reduction

device.

FG016198

Figure 71

Inspection, Maintenance and Adjustment

OP001123

4-43

Replace Hydraulic Oil Return Filter, Drain

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 72) on

instrument panel comes "ON" the return filter must be

serviced.

FG013832

Figure 72

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

FG016117

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

tank.

Figure 73

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 73) slightly to release the

internal pressure.

Remove bolts

(2, Figure

73) 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 74

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

valve and spring. Install service cover plate.

Tighten the breather cap (1, Figure 73).

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

OP001123

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

75) on

instrument panel comes "ON" the pilot filter must be

serviced.

FG013895

Figure 75

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.

FG016136

Lift the breather cap (1, Figure 73) slightly to release the

Figure 76

internal pressure.

Locate pilot system filter assembly. See Figure 76.

Unscrew canister (5, Figure 77) 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 77).

NOTE: Used filter should always be disposed of

according to local regulations.

FG000323

After changing pilot filter, vent air from pump and check

Figure 77

level of hydraulic oil tank.

Inspection, Maintenance and Adjustment

OP001123

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

FG016109

escape.

Figure 78

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 78) are in their

proper positions as shown.

Place a container under drain plug (2, Figure 78) 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 78). 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 79) slightly to release the

internal pressure.

Unscrew the bolt (1, Figure 79) and take off the breather

cap (2, Figure 79).

Change a filter cartridge (3, Figure 79) and assemble the

breather cap by tighting the bolt.

NOTE: Used filter should always be disposed of

according to local regulations.

FG013207

Figure 79

Inspection, Maintenance and Adjustment

OP001123

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"

Cover

(OFF) position.

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

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

FG016162

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

Figure 80

four wing bolts and washers, and access cover (1, Figure 80).

Open the cover by unscrewing the knob (1, Figure 81) in

the rear of the cabin.

FG000441

Figure 81

Remove filter (Figure 82) and replace with new one.

Reassemble in reverse order.

FG000342

Figure 82

Inspection, Maintenance and Adjustment

OP001123

4-47

Change Fuel Cap Filter

WARNING

External shock or damages to fuel cap may lead to

permanent damage to filter.

FG015720

Figure 83

See under the fuel cap as shown on (Figure 84). Rotate

bolt to CCW direction to loosen.

FG015684

Figure 84

After disengaging it as shown on (Figure 85), carefully lay it

on floor.

FG015685

Figure 85

After disengaging, disengage rubber as shown on (Figure

86).

FG015686

Figure 86

Inspection, Maintenance and Adjustment

OP001123

4-48

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 1,800 rpm. Operate for a minimum of

FG016137

ten minutes to stabilize the system.

Figure 89

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

OP001123

4-50

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.

FG015801

Figure 90

Set a container under excavator.

Release the drain plug (3, Figure 91) 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.

FG016119

Figure 91

Remove breather/fill cap (2, Figure 90) and add oil to "H"

mark on dipstick (1).

FG000419

Figure 92

Inspection, Maintenance and Adjustment

OP001123

4-51

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

2,000 hours of service.

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 93) and air cleaner

cover (2).

NOTE: Inspect evacuator valve seal lips for wear or

damage. Replace valve if necessary. Install

FG016134

evacuator valve with lips parallel to the cover.

Figure 93

Remove outer filter (3, Figure 93) from the air cleaner

housing.

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

housing.

Remove inner filter (4, Figure 94).

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.

FG016115

Figure 94

Inspection, Maintenance and Adjustment

OP001123

4-52

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 95

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 radiator cap to allow any pressure to escape.

Remove access covers under radiator and engine oil pan.

Place a container under drain plugs (1, Figure 96) and

drain valve (2, Figure 97). Remove drain plugs (1, Figure

96) and EGR plugs (3 and 4, Figure 98) and open drain

valve (2, Figure 97) to drain coolant.

Drain coolant from heater hoses by removing clamps (5

and 6, Figure 99) and hoses.

NOTE: Make sure heater hose shutoff valves are

FG016120

"OPENED".

Figure 96

Inspection, Maintenance and Adjustment

OP001123

4-53

Install drain plugs (1, Figure 96), EGR plugs (3 and 4,

Figure

98) and close drain valve

(2, Figure

97) after

coolant has completely drained from system. Reconnect

heater hoses with clamps (5 and 6, Figure 99).

Slowly fill cooling system with flushing solution to radiator

neck.

Run engine at low idle until coolant temperature reaches

"BLUE ZONE". Continue running engine for another five

minutes.

Shutdown engine. Remove drain plugs (1, Figure 96), EGR

FG016140

plugs (3 and 4, Figure 98) and open drain valve (2, Figure

Figure 97

97) to drain flushing fluid. Drain flushing fluid from heater

hoses after removing clamps (5 and 6, Figure 99).

Install drain plugs (1, Figure 96) and close drain valve (2,

Figure 97). Reconnect heater hoses with clamps (5 and 6,

Figure 99).

10.

Do not install EGR plugs (3 and 4, Figure 98).

11.

To prevent air from entering cooling system, slowly fill

system with coolant. Use proper antifreeze mixture for

ambient temperature.

NOTE: Refer to coolant concentration table. See

“Antifreeze

Concentration

Tables”

page 4-83.

12.

When system is filled with coolant to EGR plug holes (3

and 4, Figure 98), install plugs and continue filling to

radiator neck.

13.

Run engine for five minutes at low idle so air will be purged

from system.

14.

Loosen EGR plugs (3 and 4, Figure 98) a little and vent air.

Tighten EGR plugs.

15.

Shutdown engine and fill radiator with coolant to radiator

neck again. Install radiator cap.

FG016138

Figure 98

16.

Fill recovery tank with coolant to middle of "FULL-LOW"

after draining old coolant in recovery tank and washing it

out.

FG016139

Figure 99

Inspection, Maintenance and Adjustment

OP001123

4-54

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 100

allow the pressurized air to vent. After the pressure has

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

service covers.

IMPORTANT

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

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

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

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

used, guaranteed change interval is 1,000 hours.

NOTE: Based on the type of excavating being completed,

the working conditions (extremely hot or dusty) and

the extra front end attachments being used (hydraulic

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

changed more frequently.

Position the machine on firm, level ground. Swing upper

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

position bucket on ground as shown in Figure 101.

Set safety lever on "LOCK" position.

Shut down engine.

Release pressurized air from hydraulic tank by lifting

breather cap (1, Figure 104).

FG015805

Figure 101

Inspection, Maintenance and Adjustment

OP001123

4-55

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

FG015797

disposed of according to local regulations.

Figure 102

Carefully remove bolts and cover (2, Figure 104) from top

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

that will force the cover up.

Remove spring (3, Figure 104) and strainer (5), by pulling

on rod (4).

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

broken.

Position strainer (5, Figure 104) on boss portion of suction

pipe (6).

NOTE: Measurement "A" is 787 mm (30.98 in).

HAOC411L

Figure 103

10.

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

side of tank.

11.

Place spring (3, Figure 104) 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 4-89.

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 104

Inspection, Maintenance and Adjustment

OP001123

4-56

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

Inspection, Maintenance and Adjustment

OP001123

4-58

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 4-58,

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

OP001123

4-59

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

OP001123

4-60

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

10.5

103

mounting bracket and

fan side

735

542

engine

Joint bolt and nut

pump side

892

658

between engine mount-

fan side

892

658

ing bracket and frame

Radiator mounting bolt

265

195

Tightening bolt for hydraulic oil tank

539

398

Tightening bolt for fuel tank

539

398

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

932

687

Tightening bolt for swing motor

265

195

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

176

1726

1273

frame

Joint bolt with swing bearing and bottom

182

1785

1316

frame

Tightening bolt for travel device

883

651

Tightening bolt for sprocket

883

651

Tightening bolt for upper

pump side

520

383

roller

flange side

520

383

Tightening bolt for bottom roller

883

651

Tightening bolt for track guard

883

651

Bolt for track shoes

191

1874

1381

Inspection, Maintenance and Adjustment

OP001123

4-61

BOLT

TORQUE

NO.

POINT TO BE INSPECTED

DIA.

QTY.

HEAD

kg•m

ft lb

SIZE

265

195

Fixing bolt for front pin

392

289

Fixing bolt for track frame and side frame

288

2824

2083

Fixing bolt for fan motor

16/12

2/1

24/19

24/11

265/108

195/80

Fixing bolt for fan pump

167

123

Breaker Filter (Optional)

PF1/2

265

195

Inspection, Maintenance and Adjustment

OP001123

4-62

Joint bolt with engine mounting bracket and engine

1) Pump side

•

Tool: 19 mm (

)

•

Torque: 10.5 kg•m (103 Nm, 123 ft lb)

FG016173

Figure 105

2) Fan side

•

Tool: 22 mm (

)

•

Torque: 17 kg•m (167 Nm, 123 ft lb)

FG016083

Figure 106

Joint bolt and nut between engine mounting bracket and

frame

1) Pump side

•

Tool: 36 mm (

)

•

Torque: 91 kg•m (892 Nm, 658 ft lb)

FG016084

Figure 107

2) Fan side

•

Tool: 36 mm (

)

•

Torque: 91 kg•m (892 Nm, 658 ft lb)

FG016085

Figure 108

Inspection, Maintenance and Adjustment

OP001123

4-63

Radiator mounting bolt

•

Tool: 24 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG016086

Figure 109

Tightening bolt for hydraulic oil tank

•

Tool: 30 mm (

)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG016087

Figure 110

Tightening bolt for fuel tank

•

Tool: 30 mm (

)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG016088

Figure 111

Tightening bolt for pump

1) Main pump

•

Tool: 19 mm (

)

•

Torque: 11 kg•m (108 Nm, 80 ft lb)

2) Pump cover

•

Tool: 19 mm (

)

FG016089

•

Torque: 9 kg•m (88 Nm, 65 ft lb)

Figure 112

Inspection, Maintenance and Adjustment

OP001123

4-64

Tightening bolt for control valve

•

Tool: 30 mm (

)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG016090

Figure 113

Tightening bolt for swing reduction device

•

Tool: 36 mm (

)

•

Torque: 95 kg•m (932 Nm, 687 ft lb)

FG016091

Figure 114

Tightening bolt for swing motor

•

Tool: 14 mm (

)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

FG016092

Figure 115

10. Tightening bolt for battery

•

Tool: 17 mm (

)

•

Torque: 5 kg•m (49 Nm, 36 ft lb)

FG001592

Figure 116

Inspection, Maintenance and Adjustment

OP001123

4-65

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: 46 mm (

)

•

Torque: 176 kg•m (1,726 Nm, 1,273 ft lb)

FG016093

Figure 119

Joint bolt with swing bearing and bottom frame

•

Tool: 46 mm (

)

•

Torque: 182 kg•m (1,785 Nm, 1,316 ft lb)

FG001594

Figure 120

Inspection, Maintenance and Adjustment

OP001123

4-66

13. Tightening bolt for travel device

•

Tool: 36 mm (

)

•

Torque: 90 kg•m (883 Nm, 651 ft lb)

FG016094

Figure 121

Tightening bolt for sprocket

•

Tool: 36 mm (

)

•

Torque: 90 kg•m (883 Nm, 651 ft lb)

FG016095

Figure 122

14. Tightening bolt for upper roller

1) Fan side

•

Tool: 30 mm (

)

•

Torque: 53 kg•m (520 Nm, 383 ft lb)

FG016096

Figure 123

2) Flange side

•

Tool: 30 mm (

)

•

Torque: 53 kg•m (520 Nm, 383 ft lb)

FG016097

Figure 124

Inspection, Maintenance and Adjustment

OP001123

4-67

15. Tightening bolt for bottom roller

•

Tool: 36 mm (

)

•

Torque: 90 kg•m (883 Nm, 651 ft lb)

FG016098

Figure 125

16. Tightening bolt for track guard

•

Tool: 36 mm (

)

•

Torque: 90 kg•m (883 Nm, 651 ft lb)

FG016099

Figure 126

17. Bolt for track shoes

Tighten the bolts in the order as shown in the Figure 127 (1

→ 4)

•

Tool: 36 mm (

)

•

Torque: 191 kg•m (1,874 Nm, 1,381 ft lb)

FG016171

Figure 127

18. Fixing bolt for front pin

1) Arm end side

•

Tool: 24 mm (

) (1)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

•

Tool: 30 mm (

) (2)

•

Torque: 55 kg•m (392 Nm, 152 ft lb)

FG016147

Figure 128

Inspection, Maintenance and Adjustment

OP001123

4-68

2) Arn cylinder, boom cylinder side

•

Tool: 24 mm (

) (1)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

•

Tool: 30 mm (

)

(2)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG016148

Figure 129

FG016151

Figure 130

3) Bucket side

•

Tool: 24 mm (

) (1)

•

Torque: 27 kg•m (265 Nm, 195 ft lb)

•

Tool: 30 mm (

)

(2)

•

Torque: 55 kg•m (539 Nm, 398 ft lb)

FG016149

Figure 131

FG016150

Figure 132

Inspection, Maintenance and Adjustment

OP001123

4-69

BUCKET

Bucket Tooth Replacement

WARNING

Due to the possibility of flying metal objects, always wear

safety helmet, protective gloves and eye protection when

changing bucket teeth.

Curl the bucket upwards and place the round rear surface

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

lock out the hydraulic controls before working on the

bucket.

NOTE: These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers

buckets, refer to their specific instructions.

HAOC680L

Figure 137

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

tooth wear or breakage has not developed. Do not allow

replaceable bucket teeth to wear down to a point that

bucket adapter is exposed. See Figure 137.

To replace a tooth (1, Figure 138), use a hammer and

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

tooth adapter (4).

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

scrape adapter as clean as possible.

Slide new tooth into position and insert lock washer.

FG000346

Figure 138

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

until lock washer seats in locking groove.

Inspection, Maintenance and Adjustment

OP001123

4-72

Bucket O-ring Replacement

WARNING

Due to possibility of flying metal objects, always wear

safety helmet, protective gloves and eye protection when

changing pins.

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

FG000502

damaged, replacement is necessary.

Figure 139

Roll old O-ring (1, Figure 140) onto boss (2) around bucket

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

(4) out of way.

ARO1390L

Figure 140

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

Figure 141) onto bucket boss (2). Make sure that O-ring

groove on both bucket link

(4) and boss have been

cleaned.

Realign arm or link with bucket pin hole and insert bucket

pin (3, Figure 140).

ARO1391L

Figure 141

Roll new O-ring (1, Figure 142) into O-ring groove.

ARO1392L

Figure 142

Inspection, Maintenance and Adjustment

OP001123

4-73

BUCKET SHIMMING

PROCEDURES

New Bucket Installation

If a new bucket is being installed on the excavator,

measure the inside dimension between the bucket ears

and the outside dimension across the arm mounting boss.

Subtract the clearance on both sides from the difference of

the two and shim accordingly, before assembly.

WARNING

To check end play

(side-to-side) clearance at bucket

attachment point, the bucket must be free to move but at all

other times lower it to the ground or use support blocks to

immobilize this assembly. Shut off engine and tag and lock

out controls to prevent movement during this procedure.

Shimming Procedures for Installed Bucket

"Y"

With bucket attached, curl bucket and arm outward and

lower boom so that bucket teeth are pointing away from

excavator, just a few inches off ground. This position

provides easy accessibility for dimensional measurements.

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

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

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

boss and inside edge of ear bushing (Y, Figure 143). Too

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

wear while too much clearance may produce excessive

noise and potentially hazardous slack control.

Recheck end play by forcing bucket towards opposite side

and repeating clearance measurements.

FG016145

If an adjustment is required, remove two jam nuts (1,

Figure 143

Figure 143) and bolt (2) from pin (3). Add or remove shims

(4) as required. Use an equal amount of shims on each

side. Install bolt (2) and two jam nuts (1). Jam nuts must

clear boss by 1 - 2 mm (0.04 - 0.08 in) at point (X).

Inspection, Maintenance and Adjustment

OP001123

4-74

ELECTRICAL SYSTEM

NOTE: Never disassemble electrical or electronic parts.

Consult with a DOOSAN distributor or sales agency

before servicing.

Battery

WARNING

Battery electrolyte contains sulfuric acid and can quickly

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

yourself, immediately flush the area with water.

Battery acid could cause blindness if splashed into the

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

large quantities of water and see a doctor at once.

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

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

prevention center immediately.

When working with batteries, always wear safety glasses or

goggles.

Battery generates hydrogen gas, so there is danger of an

explosion. Do not bring lighted cigarettes near the battery,

or do anything that will cause sparks.

Before working with batteries, shut down engine and turn

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

Avoid short circuiting the battery terminals through

accidental contact with metallic objects, such as tool.

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

terminal and negative (-) terminal.

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

terminal. When installing the battery, first connect the

positive (+) terminal.

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

contact may generate sparks that will cause an explosion.

When installing the terminals, install them tightly.

Batteries in Cold Weather

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

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

engine. Battery performance decreases as the temperature gets

lower.

In extremely cold weather, remove the batteries at night and

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

higher power level.

Inspection, Maintenance and Adjustment

OP001123

4-75

Inspection of Battery Electrolyte Level

This machine has two maintenance free batteries. They never

require the addition to water.

When the charge indicator becomes transparency, it means low

electrolyte state because of the leakage or charging system

error. Determine the cause of problem and replace the batteries

immediately.

FG000347

Figure 144

Check Charging State

Check charging state through the charging indicator.

•

GREEN: Sufficiently charged.

•

BLACK: Insufficient charged.

•

TRANSPARENT: Replace battery.

Check the Battery Terminals

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

Clean the battery terminals and the battery cable connectors. A

solution of baking soda and water will neutralize acid on the battery

surface, terminals, and cable connectors. Petroleum jelly or grease

can be applied to the connectors to help prevent corrosion.

Battery Replacement

When the charging indicator indicates transparency state, replace

the battery. The batteries should always be replaced in pairs.

HAOU790L

Figure 145

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

the new battery.

Inspection, Maintenance and Adjustment

OP001123

4-76

Fuses

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

electrical circuits and their components from being

damaged. See Figure 146. The fuses used are standard

automotive type fuses.

The section on “Fuse Identification” on page 4-78, lists the

circuits and the fuse amperage required for each circuit. If

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

failures.

Do not insert a higher amperage fuse into a lower

amperage slot. Serious damage to the electrical

components or fire can result.

HAOC670L

Figure 146

CAUTION

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

(OFF) position.

Fuse Boxes

There are two fuse boxes (Figure 147) on the left side of the

heater box. The fuses prevent electrical devices from

overloading or shorting.

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

the function and amperage of each fuse.

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

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

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

FG000110

fuse separates, check the circuit and repair the circuit.

Figure 147

CAUTION

Always replace fuses with the same type and capacity fuse

that was removed. Otherwise, electrical damage could result.

Inspection, Maintenance and Adjustment

OP001123

4-77

Fuse Identification

Fuse Box (1)

Fuse Box (2)

FG000542

Figure 148

Fuse Box One

Fuse Box Two

No.

Name

Capacity

Name

Capacity

Warning Light (Optional)

10A

Horn

10A

2-pump (Optional)

10A

Quick Clamp (Optional)

10A

Cigar Lighter

10A

Travel Alarm (Optional)

10A

12V Power

10A

Auxiliary Mode

10A

Wiper, Washer

10A

Check Connector

10A

Lower Wiper (Optional)

10A

Pilot Cutoff

10A

Stereo

10A

Memory Backup

10A

Starter Switch, Hour Meter

10A

Room Light

10A

Spare

30A

Cabin Light (Optional)

30A

Air Conditioner, Heater

20A

Work Light

20A

Shear, Breaker (Optional)

15A

Fuel Heater

20A

Seat Heater (Optional)

15A

Instrument Panel, Pressure Sensor

15A

e-EPOS, Booster, Travel speed

15A

Headlight

15A

changer, Booster

ECU

15A

Fuel Pump (Optional), Wiper

15A

Inspection, Maintenance and Adjustment

OP001123

4-78

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.

Make at least a minimum mixture of 40% antifreeze with 60%

distilled water for adding additional fluid to the system during

normal maintenance. This level will help maintain the additive

concentration of the system. Check the coolant every 500 hours.

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.

CAUTION

Maintaining the proper anticorrosive additive levels in

antifreeze will help protect the engine and other

components from becoming corroded.

If anticorrosive additive levels are not properly maintained

and monitored, server damage to the cooling pump and

cylinder liners may result. This corrosion can also result in

the radiator tubes becoming clogged and loosing their heat

transfer efficiency. The engine

(Model: DV11) uses a

wet-type cylinder liner design, which requires, a high

efficiency cooling system flow, to maintain proper engine

temperatures.

The coolant and its additives can be checked by using

coolant test paper (No: 60.99901-0038).

WARNING

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

psi). Always wear goggles when using compressed air.

Do not pour cold water into radiator when engine is very

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

action could result in damage to engine cylinder heads.

Inspection, Maintenance and Adjustment

OP001123

4-79

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.

Measuring the Concentration of Coolant

The coolant and its additives can be checked by using coolant

test strips (No: 60.99901-0038). Use the following procedure to

conduct the test:

With a coolant temperature of 10° - 55°C (50° - 131°F),

drain 1 liter (1 U.S. quart) it from the radiator into a clean

plastic container.

NOTE: Do not take the sample from the coolant

recovery tank. Recovery tank coolant

concentration can differ from the concentration

level of coolant in the radiator.

Dip test strip, into coolant sample for

3 -

5 seconds.

Remove strip and excessive coolant by giving the strip one

shack.

Wait for 45 seconds, for the test strip to change color.

NOTE: Measuring time should not be more than 75

seconds. If it is over this time limit, the color will

be changed and an inaccurate reading will

result.

Compare the color of the test strip with the color table on

the outside of test strip container bottle, and determine

what numeric value corresponds to the color in the table.

A. Check antifreeze concentration levels by comparing

the color change at the end of test paper, with the

green spectrum range, with the green symbol on the

upper portion of the container bottle.

NOTE: A suitable concentration indicator should

be between 33% and 50%).

B. Check the anticorrosive additives, by comparing

brown color in the middle range of the test strip and

pink color on the lower part of the test strip, with the

brown and pink spectrum range. Where the brown

(vertical) color and pink (horizontal) color intersects

represents the anticorrosive additive level.

NOTE: A reading between 0.3 and 0.8, represents

an adequate additive level.

Correct the antifreeze concentration and additive levels.

Inspection, Maintenance and Adjustment

OP001123

4-80

A. If anticorrosive additive level is below 0.3, add 100%

pure antifreeze to the radiator.

B. If anticorrosive additive level is greater 0.8, add a

50% distilled water and antifreeze mixture to lower

the additive reading.

NOTE: In either case keep the antifreeze concentration

level between 33% and 50%.

Run the engine to recirculate the coolant mixture. Be sure

that engine reaches operating temperature to ensure a

thorough mix. Shut down engine and retest antifreeze.

NOTE: When making adjustment, drain 1 liter (1 U.S.

quart) of coolant from the radiator. Add 30 cc (1

fl oz) at a time to the drained fluid. Keep track of

how many cc's (fl oz's) were added to the 1 liter

(1 U.S. quart) to obtain a proper reading. Then

multiply that number times the total system

capacity of liters (U.S. quarts). Add that amount

to the radiator.

Example: If 1 liter needs 90 cc to obtain proper

reading. Then system capacity of

liters x 90 cc

= 3,600 cc (3.6 liters) of

correction fluid.

Inspection, Maintenance and Adjustment

OP001123

4-81

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

OP001123

4-82

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

OP001123

4-83

FUEL TRANSFER PUMP

(OPTIONAL)

WARNING

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

•

Cooling and lubrication of pump is achieved by

fuel passing through pump. If pump is dry

operated, heat generated by moving parts will

cause damage to pump rotors, vanes and seals.

To prevent unnecessary wear and/or damage to

pump do not dry operate fuel pump for more than

fifteen seconds.

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

•

Continuous usage of pump over recommended

time interval will cause overheating of motor and

will result in causing motor damage.

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

(Use only for diesel fuel.)

•

Do not use refueling pump for other types of fuel

which have a low flash point.

•

Do not use refueling pump for fuel contaminated

with water or high humidity. Moisture in pump

mechanism can cause rust and can create pump

failure.

Always operate pump using strainer installed on inlet hose.

This will prevent any foreign materials from being

introduced into pump. Always maintain pump and all of its

components in a clean condition.

•

If dirt or other foreign materials enter pump, it can

become lodged between the rotor and/or vanes and

generate heat which can cause pump damage.

•

Do not remove strainer or use a strainer with

larger mesh to increase flow of fuel.

Be careful not to overfill or spill fuel.

Make sure direction of check valve is in line with flow

direction of fuel.

If any pump parts or components become lost, damaged or

inoperable, immediately replace it with a new ones.

IMPORTANT

If there are any sign of leakage while operating transfer

pump, inspect the following components to prevent any

fires or hazardous fuel spills.

•

Check all hoses leading to and from the transfer

pump.

•

Check all hose clamps.

•

Check transfer pump inlet port.

Inspection, Maintenance and Adjustment

OP001123

4-84

The transfer pump is used to transfer fuel from a refueling

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

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

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

from being introduced into transfer pump or fuel tank.

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

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

Fuel

Fuel Tank

OUT

FG016185

Figure 149

Reference

Description

Number

Body

Inlet Hose

Check Valve

Insert inlet hose (3, Figure 149) into refueling tank.

Turn fuel pump "ON" press (Figure 150) inside of battery

box on front side.

NOTE: Transfer pump rate of flow is approximately 100

liters/minute (26.4 U.S. gpm). Use extra care

not to overfill fuel tank so that fuel does not over

flow.

Once fuel transfer is completed automatically "OFF"

position to stop pump.

Lift inlet hose (3, Figure 149) from fueling source and turn

FG015806

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

Figure 150

remaining fuel from hose to fuel tank.

Inlet strainer and return hose (3) to storage position.

Inspection, Maintenance and Adjustment

OP001123

4-85

HANDLING OF ACCUMULATOR

WARNING

Even though the engine is stopped, the hydraulic

accumulators for the pilot system are still charged. Do not

disconnect any pilot system hoses until accumulator

pressure has been released from the circuit. To release

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

operate all hydraulic control levers and forward/reverse

travel levers. Even though the engine is shutdown hydraulic

actuated components may move while releasing pilot

pressure. Keep all personnel away from excavator while

performing this operation.

•

Set safety lever on "LOCK" position after

stopping engine.

•

DO NOT mishandle accumulator(s). They are very

dangerous because they contain high-pressure

nitrogen gas.

•

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

accumulator.

•

DO NOT weld on accumulator, or try attaching

anything to it.

•

When replacing an accumulator, contact a

DOOSAN distributor or sales agency so the gas

can be properly released.

•

Wear safety goggles and protective gloves when

working on an accumulator. Hydraulic oil under

pressure can penetrate the skin and cause

serious injuries.

Release pilot accumulator pressure using the following

procedure;

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

attachment to the ground and shut down engine.

Set safety lever on "RELEASED" position.

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

Fully stroke work and travel levers in all directions.

Set safety lever on "LOCK" position.

FG016144

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

Figure 151

switch.

Remove accumulator by unscrewing it slowly.

Inspection, Maintenance and Adjustment

OP001123

4-86

TRACK TENSION

WARNING

Safely measuring track tension requires two people. One

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

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

makes dimensional checks. Take all necessary precautions

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

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

the excavator to an area that provides level, uniform ground

support and/or use support blocks when necessary.

The track adjusting mechanism is under very

high-pressure. NEVER release pressure too suddenly. The

grease cylinder valve should never be backed off more than

one complete turn from the fully snugged down position.

Bleed off pressure slowly and keep your body away from

the valve at all times.

Track shoe link pins and bushings wear with normal usage,

reducing track tension. Periodic adjustment is necessary to

compensate for wear and it may also be required by working

conditions.

Track tension is checked by jacking up one side of the

excavator. See Figure 152. Place blocking under frame

while taking measurement.

90 ~ 110

FG015779

Figure 152

Measuring the distance

(A, Figure

153) between the

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

shoe. Recommended tension for operation over most

types of terrain is 380 - 430 mm (14.96 - 16.93 in)

NOTE: This measurement can be thrown off if there is

too much mud or dirt or other material in the

track assembly. Clean off the tracks before

checking clearance.

Too little sag in the crawler track

(less than

380 mm

(14.96 in) clearance) can cause excessive component

FG000162

wear. The recommended adjustment can also be too tight

Figure 153

causing accelerated stress and wear if ground conditions

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

of rocks or gravel.

Inspection, Maintenance and Adjustment

OP001123

4-87

The increased clearance recommended for muddy ground

conditions is between 430 - 460 mm (16.93 - 18.11 in). The

clearance should be approximately 460 mm (18.11 in) for

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

WARNING

The track adjusting mechanism is under very

high-pressure. NEVER release pressure too suddenly.

The grease cylinder valve should never be backed off

more than 1 complete turn from the fully snugged

down position. Bleed off pressure slowly and keep

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

problem in the fitting thread, the valve or fitting might

be ejected at high speed to cause fatal wound.

Track tension adjustments are made through the grease

fitting

(1, Figure 154) in the middle of each side frame.

Adding grease increases the length of an adjustment

cylinder

(2). The longer the adjustment cylinder, the

greater the pressure on the tension spring pushing the

track idler wheel outward.

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

the adjustment is too tight, the idler wheel and adjusting

cylinder can be retracted by bleeding off grease through

hole in valve (3, Figure 154) by loosening valve slowly.

FG016146

NOTE: After track tension is adjusted by loosening

Figure 154

valve, be sure to tighten valve (3, Figure 154)

with 27 kg•m (265 Nm, 195 ft lb).

WARNING

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

154) until the pressure is entirely bleed off by slowly

loosening valve (3, Figure 154).

Inspection, Maintenance and Adjustment

OP001123

4-88

VENTING AND PRIMING

HYDRAULIC SYSTEM

Main System Pump

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

hydraulic pump, damage can occur. Always vent

pump of air after draining hydraulic system.

Shut down engine.

Remove flushing hose (1) from the adapter (2).

Remove adapter (2) and O-ring from the pump housing.

Fill pump housing with hydraulic oil.

Install new O-ring onto adapter

(2) and assemble the

FG016141

adapter on pump housing.

Figure 155

Connect flushing hose (1) to adapter (2).

Start engine, and run at "LOW IDLE". Raise boom to its

maximum height.

Very slowly loosen negative control hose connector (3)

until hydraulic oil start to leak from the connection.

When hydraulic oil begins to leak, tighten hose connector.

10.

Shut down engine, turn starter switch "ON", and slowly

lower the boom until the bucket pin touches the ground.

(This will increase the air pressure in the hydraulic tank)

11.

Slowly loosen air bleeding plug (4) until hydraulic oil leaks

out.

12.

When hydraulic oil begins to leak, then tighten plug (4).

Hydraulic Cylinders

IMPORTANT

If cylinders are operated in high idle after the hydraulic

system has been drained or the cylinder has been rebuilt,

damage to piston packing and seals may occur. Always

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

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

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

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

Repeat procedure until cylinders extend and retract

smoothly.

Inspection, Maintenance and Adjustment

OP001123

4-89

Swing Motor

IMPORTANT

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

to the swing motor and bearings.

NOTE: Perform this only when oil has been drained from

swing motor.

FG016142

Shut down engine.

Figure 156

Disconnect drain hose and fill swing motor case with

hydraulic oil.

Connect the drain hose.

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

upper structure slowly two full revolutions to the left and

right.

Travel Motor

NOTE: Perform this only when oil is drained from travel

motor

Shut down engine

Disconnect drain hose (Figure 157) and fill motor case with

hydraulic oil.

Connect drain hose.

Start engine and set engine speed control dial to "LOW

FG016143

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

Figure 157

excavator forwards and backwards.

General Venting

After venting air from all components, shut the engine

down and check the hydraulic oil level. Fill hydraulic oil

tank to "H" mark on sight gauge.

Start engine and operate all controls again, run engine for

five minutes to ensure all systems have been vent and

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

hydraulic oil level again. Add oil as necessary.

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

Inspection, Maintenance and Adjustment

OP001123

4-90

LONG TERM STORAGE

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

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

Leaving equipment outdoors exposed to the elements will

shorten its life.

An enclosure will protect the machine from rapid temperature

changes and lessen the amount of condensation that forms in

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

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

FG016154

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

Figure 158

natural disasters.

After the machine has been positioned for storage and the

engine shut down, perform the following operations:

Before Storage

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

rust of the hydraulic piston rods.

•

Inspect for damaged, loose or missing parts.

•

Repaint necessary area to prevent oxidation.

•

Wash and clean all parts of machine.

•

Store the machine indoor, stable place. If stored

outside, cover with a waterproof tarpaulin.

•

Perform lubrication procedures on all grease points.

•

Apply a coating of light oil to the exposed plated

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

and to all the control linkage and control cylinders.

(Control valve spools, etc.)

•

Remove the battery from the excavator to be fully

charged and stored.

•

Inspect the coolant recovery tank and radiator to

make sure the antifreeze level in the system is

correct. Make sure that antifreeze concentration is

enough for the lowest temperature anticipated during

storage.

•

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

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

with tape wide enough to cover the opening,

regardless of size.

NOTE: When sealing with tape, be sure to extend

tape approximately one inch

(25 mm)

beyond opening to insure a good seal.

Inspection, Maintenance and Adjustment

OP001123

4-91

During Storage

•

Once a month, start the engine and follow the

"Hydraulic Oil Warm-up" procedures listed in this

manual.

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

crankcase and hydraulic breathers, engine

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

Operate hydraulic functions for traveling, swing and

digging two or three times for lubrication after

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

and surfaces of the components with a new oil film

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

Rotate track to prevent track seizing. "

•

Every 90 days, use a hydrometer to measure the

protection of the coolant. Refer to the antifreeze/

coolant protection chart to determine protection of the

cooling system. Add coolant as required.

After Storage

•

When operating the work equipment, remove all

grease from the hydraulic cylinder rods.

•

Add grease and oil at all lubrication points.

•

Adjust fan and alternator belt tension.

•

Connect the charged battery.

•

Check condition of all hoses and connections.

•

Check the levels of engine oil, fuel, coolant and

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

all the oil.

•

Change all filter elements.

•

When starting the engine after long-term storage,

follow the "Hydraulic Oil Warm-up" procedures listed

in this manual.

Inspection, Maintenance and Adjustment

OP001123

4-92

Doosan DX700LC. Operation and Maintenance Manual (2010) - page 4