Doosan DX300LC. Operation and Maintenance Manual (2010)

Work Levers (Joysticks) (BHL Style)

Left-hand Work Lever (Joystick) (Figure 48 and Figure 50)

Boom down

Boom up

Left swing

Right swing

NOTE: The swing brake is spring applied and

hydraulically released. It is always engaged

when the work lever (joystick) is in "NEUTRAL"

or the engine is shut down.

FG004951

Figure 50

Right-hand Work Lever (Joystick) (Figure 48 and Figure 51)

Arm dump

Arm crowd

Bucket crowd

Bucket dump

NOTE: The following is not a mechanical malfunction

but a proper phenomenon of the excavator.

When operating the arm, it may stop

momentarily. When the arm is operated, the

FG004952

weight of the arm may cause it to move faster

Figure 51

than the amount of oil being supplied.

NOTE: Even after stopping the engine, the front can be

lowered to the ground by operating work lever

(joystick), by setting safety lever on "UNLOCK"

position and turning starter switch "ON."

FG000120

Figure 52

Operation

OP001173

3-25

OPERATING PRECAUTIONS

WARNING

Do not rest your feet on the travel pedals during normal

machine operation. Unexpected machine travel may occur

in this situation.

Before starting work, investigate terrain and soil condition.

Level ground and drain area if necessary.

Install window guards when working where there is a

possibility of falling rocks or other objects.

FG000374

Figure 53

Check strength of supported structures in advance before

working on them. If insufficient, reinforce it. If any doubt

exists about structural strength, refuse to operate unit.

It is possible that the boom, arm or bucket may come into

contact with the upper or lower structure of the machine.

There are digging conditions which could allow this to

happen.

FG000375

Figure 54

Do not continually "bottom out" the hydraulic cylinders.

Machine damage may occur if the cylinders are fully

extended or retracted, example: arm cylinder fully retracted

and the bucket cylinder is extended to rotate the bucket

into the ground.

FG000132

Figure 55

Operation

OP001173

3-26

Do not use machine travel or swing when the bucket is in

the ground to provide additional breakout force. See Figure

56.

FG000134

Figure 56

Do not use weight of machine to provide additional

breakout force. See Figure 57.

When working on soft or muddy ground, make sure that

machine is not sinking.

FG000137

Figure 57

When working close to the excavated edge, make sure

that ground the machine is sitting on is solid. Keep the

travel motors (1, Figure 58) to the rear. See Figure 58.

FG000677

Figure 58

10. Do not excavate underneath the machine. See Figure 59.

FG000170

Figure 59

Operation

OP001173

3-27

11. Make sure there is adequate clearance from overhead

electrical supply lines. See Figure 60.

FG000171

Figure 60

12. If the excavation is in an underground location or in a

building, make sure there is adequate overhead clearance

and there is adequate ventilation. See Figure 61.

FG000172

Figure 61

13. Do not use the bucket as a hammer or ramming device.

This is dangerous and causes damage to the front

attachment. See Figure 62.

FG000173

Figure 62

14. Do not dig with the excavator tracks raised. This can result

in structural and mechanical failures.

FG000174

Figure 63

Operation

OP001173

3-28

15. Do not operate travel lever quickly when traveling in high

range.

•

Avoid sudden starts.

•

When traveling in one direction come to a complete

stop before reversing directions. Do not rock

excavator back and forth with levers.

•

Avoid sudden stops. Return levers to neutral by

hand. Do not let them snap back to neutral on their

own.

FG000213

16. If the optional long fronts or attachments or heavy duty

Figure 64

front end attachments are used, the machine balance will

be altered. Follow these additional operating precautions.

WARNING

Do not travel downhill with the front end attachments

raised.

Do not travel across slopes; travel straight up or

downslope.

Use extreme caution when swinging the upper frame

when positioned on a slope.

Allow extra swing stopping room. The additional

momentum generated by the longer or heavier front

end equipment will increase the amount of time

needed to stop the swing motion.

Make sure that all optional equipment has been

authorized and installed properly.

17. Do not move dirt or objects by swinging the excavator into

them. This can result in structural and mechanical failures.

Operation

OP001173

3-29

Working in Water

IMPORTANT

When working in water, do not exceed a slope of more than

15°. If the slope is over 15°, the rear part of the upper

structure will be immersed in water, resulting in radiator fan

and engine ECU damage.

FG000179

Figure 65

When working in water, do not operate in water over center of

upper roller (1, Figure 66).

If swing bearing gets wet, immediately grease it until all old

grease is purged from bearing.

If water gets into swing gear housing, drain water immediately

by removing lower inspection cover. Apply new grease.

After working in water, purge old grease on bucket pins.

FG000181

Figure 66

Operation

OP001173

3-30

PARKING EXCAVATOR

WARNING

120

Park excavator on firm, level ground. Avoid parking on

slopes. If excavator must be parked on a slope, block tracks

and place bucket teeth in ground. See Figure 67.

FG000214

Figure 67

Park excavator on firm, level ground. Lower bucket to

ground as shown in Figure 68.

FG000111

Figure 68

Set engine speed control dial on "LOW IDLE."

HAOB290L

Figure 69

If you touch the operation lever unintentionally, it may

create a serious accident. Before leaving operator's seat,

set safety lever on "LOCK" position.

Unlock

Lock

FG015867

Figure 70

Operation

OP001173

3-31

TOWING PROCEDURE

Cloth

WARNING

Never use a damaged wire rope or chain. They could brake

and cause a serious accident.

Towing Wire

Always wear gloves when handling a chain or wire rope.

When towing excavator use a wire rope or chain capable of

handling the load.

Attach chain or wire rope to track frame as shown in Figure

71.

Insert protective material such as thick cloths between

track frame and wire rope to prevent the wire rope from

being damage.

Towing Wire

FG014871

IMPORTANT

Figure 71

Use shackle hook on track frame to only haul objects that

weigh less than 5 metric tons (5.51 U.S. Tons). Never use it

to haul objects over 5 metric tons (5.51 U.S. Tons).

Operation

OP001173

3-32

HYDRAULIC BREAKER

IMPORTANT

If a hydraulic breaker and piping is installed without

DOOSAN's authorization, it may create a serious

malfunction which will not be covered under the excavator

warranty.

Selection of Hydraulic Breaker

If a hydraulic breaker is installed, consider equipment's stability

and suitability for such modification. Also, consider hydraulic oil

pressure and quantity. When selecting a hydraulic breaker

consult with a DOOSAN distributor or sales agency.

Hydraulic Hoses and Tubing for Breaker

When installing hydraulic breaker, assemble according to

drawings provided with kit.

If breaker is taken off excavator, be sure to plug and cap all

hoses and tubing to prevent contamination from entering

hydraulic system.

Plug and cap all connectors and fittings on breaker to

prevent contamination.

Check all hydraulic connections for signs of leaks or loose

components before starting operation.

Operation

OP001173

3-33

Hydraulic Breaker Operation

NOTE: Hydraulic pressure and flow settings may need to be

changed. Refer to the Maintenance Section of this

manual for further information.

Make sure to read and understand the breaker user's

manual.

Inspect all mechanical and hydraulic connections.

Do not use the breaker as a hammer. See Figure 72.

Do not drop breaker from extreme heights.

The breaker is relatively heavy and drops fast. Do not drop

breaker from extreme heights or damage to upper

structure may result.

FG000188

Figure 72

Do not operate the breaker with the boom or arm cylinders

fully extended (bottomed out). See Figure 73.

Leave over 100 mm (4 in) of clearance between rod end of

cylinder and cylinder head. This will help prevent damage

to cylinders during breaker operation.

FG000191

Figure 73

Do not use the breaker if the hydraulic hoses vibrate

excessively. See Figure 74. Check the breaker's hydraulic

accumulator (1) for damage and repair as required. If

excavator is operated under this condition, structural and

hydraulic components can be damaged.

FG000215

Figure 74

Operation

OP001173

3-34

Do not allow the breaker body to go into water if not

equipped for underwater operation. The breaker seal can

be damaged and allow rust, foreign material or water to

enter the hydraulic system and cause damage. Only insert

the breaker tool into water. See Figure 75.

HAOB970L

Figure 75

Do not any lifting or towing with a breaker. See Figure 76.

FG000207

Figure 76

Operate the breaker only to the front and rear of the

excavator. Do not use the breaker to either side of the

excavator. Do not swing the breaker from side to side

when operating it. See Figure 77.

WARNING

Operating a breaker with the upper body turned 90° to

the tracks can result in tipping over the machine or

reduction in service life.

HAOB990L

Figure 77

Do not curl the breaker tool tip into the arm or boom when

traveling or parking the excavator. See Figure 78.

FG000216

Figure 78

Operation

OP001173

3-35

To activate breaker

Set breaker selector switch to "II" (BREAKER) position.

Press lower button on top of right-hand work lever

(joystick) to activate hydraulic breaker.

Release lower button on top of right-hand work lever

(joystick) to deactivate hydraulic breaker.

FG016035

Figure 79 RIGHT-HAND WORK LEVER

(JOYSTICK)

Relief Valve Adjustment

Cap pipe on arm end, using a cap capable of handling 343

bar (5,000 psi) under the condition of disconnecting hose

to hydraulic breaker.

Adjust pump pressure using activating the breaker, and

watching the pressure displayed on the instrument panel.

Press the display selector button to show digital pressure

reading. (A separate pressure gauge is not required.)

Adjust the relief valve pressure by turning the adjustment

screw of breaker relief valve. The relief valve is installed on

the left side of the upper structure behind the boom. (Do

not use the overload relief valve on the lower part of control

valve for the breaker relief valve.)

FG000777

Figure 80

WARNING

If the relief valve pressure is adjusted while the

hydraulic breaker is connected, there is possibility

that a high-pressure spike or setting could break a

hose or pipe. Personal injury or death could result

from a hydraulic hose or pipe failure.

Operation

OP001173

3-36

Hydraulic Oil and Filter Service Intervals

When using a hydraulic breaker, the viscosity breakdown and

contamination of hydraulic oil is faster because the work

condition is more severe than during normal digging work. To

prevent the hydraulic components

(especially pump) from

having a shortened life cycle, replace the hydraulic oil and main

hydraulic oil return filter using the following schedule.

Attachment

Operation Rate

Hydraulic Oil

Filter

250 Hours (First Replacement)

Bucket Work

100%

2,000 Hours

1,000 Hours (After First Replacement)

Hydraulic Breaker

100%

500 Hours

100 Hours

Work

These service intervals only apply, when a genuine DOOSAN oil and filter are used. If any other

brands are used, the guaranteed changed interval should be reduced in half.

100

105

116

551

106

144

614

FILTER

692

112

171

(First Replacement)

119

214

782

128

275

893

HYDRAULIC OIL

137

335

1028

FILTER

156

412

(After First Replacement)

1196

175

500

1400

206

635

1658

500

1000

1500

2000

MACHINE OPERATING HOURS

FG000767

Figure 81

NOTE: The replacement intervals of hydraulic oil and filter

depend upon the amount of time the hydraulic

breaker is being used. These intervals should be

followed as opposed to regularly scheduled

maintenance.

Operation

OP001173

3-37

ADJUSTING THE PUMP FLOW

NOTE: For further information, see

“Flow Control” on

page 2-44.

On the instrument panel, press the flow control button

, the flow control screen (Figure 82) will be displayed.

Use "UP" (

) or "DOWN" (

) buttons to adjust flow rate.

Press "SELECT" (

) button, to return to normal display

screen and save the flow rate setting.

FLOW CONTROL

: APPLY

ESC: CANCEL

FG013831

Figure 82

Setting

Flow Rate (l/min)

106

126

144

161

178

198

217

228

229

Operation

OP001173

3-38

Shear Pedal Valve (Optional)

Activating Shear with Pedal Valve

Select "SHEAR" with selector switch on right panel.

Make sure that stopper (Figure 85) is in "SHEAR" position.

NOTE: When stopper is in "SHEAR" position, pedal

valve can be moved/rocked in both directions.

Two-way operation is possible by rocking pedal back and

forth between positions (1 and 2, Figure 83). When pedal is

in its center (at rest) position, valve is in "NEUTRAL" and

hydraulic oil flow is stopped.

FG000402

Before operating attachment, be sure to check function

Figure 83

controlled by direction of pedal movement.

Activating Breaker with Pedal Valve

Select "BREAKER" with selector switch on right panel.

Make sure that stopper

(Figure

85) is in "BREAKER"

position.

NOTE: When stopper is in "BREAKER" position, pedal

valve can be only moved in one direction.

With the stopper in "BREAKER" position, pedal can only

be pressed in direction (1, Figure 83). When pedal is in its

center

(at rest) position, valve is in "NEUTRAL" and

FG000403

hydraulic oil flow is stopped.

Figure 84

Stopper Positions

The stopper has three positions;

Shear

Breaker

Locked

Rotate knob (3, Figure 84) clockwise in direction of arrow.

The stopper (4) then engages or disengages the pedal

Breaker

bracket

(5). The pedal can then function according to

displayed symbol shown by knob rotation.

Lock

Shear

FG014607

CAUTION

Figure 85

When only operating breaker or shear using joystick

button(s), and it is not being controlled by pedal, make

sure stopper is in "LOCKED" position to prevent pedal

from being activated.

Operation

OP001173

3-39

Rotating Pedal Valve (Optional)

Attachment Rotating by Using the Pedal Valve

Pressing end (1, Figure 86) is used to turn clockwise.

Pressing end

(2, Figure

86) is used to turn

counterclockwise.

NOTE: Before activating the pedal, be sure to check

the function of the attachment.

FG000405

Figure 86

Locking the Pedal

When rotating is not needed, the pedal can be locked by using

the prop rod (3) locking device.

Locking is completed when the top end of the prop (3) is

positioned into pedal hole.

FG000406

Figure 87

A. Location for "UNLOCKING."

B, Location for "LOCKING."

FG000407

Figure 88

Attachment Rotation Using the Left-hand Work Lever

(Joystick)

For a machine equipped with an attachment that rotates,

rotation is activated while one of the control buttons is being

pressed on top of the left-hand work lever (joystick).

There are three buttons on top of the left-hand work lever. The

left and right ones are for controlling rotation.

NOTE: The middle button is for the horn.

Left button is for counterclockwise rotation, and the right one is

FG000035

for clockwise rotation.

Figure 89 LEFT-HAND WORK LEVER

(JOYSTICK)

Operation

40OP001173

3-40

OPERATING TECHNIQUES

Lifting

IMPORTANT

There may be local or government regulations, about the

use of excavators for the lifting of heavy loads. Always

contact your local and government agencies in regards to

these regulations.

To prevent injury, do not exceed the rated load capacity of the

machine. If the machine is not on level ground, load capacities

will vary.

Short slings will prevent excessive load swing.

Use the lifting eye on the bucket that is provided to lift objects.

Always try to maintain the lifting eye (Figure 90) straight below

the center line of the arm and bucket pin. In this manner the

weight of the load is being primarily held only by the pin, and not

by the bucket cylinder, link, and link pins.

When a lifting eye is used, the sling/lifting device must be

fastened to the eye in a manner that will not allow it to come

loose.

The most stable position is over the corner of the machine.

For best stability, carry a load as close to the ground and

machine as possible.

HAAD3830

Lift capacity decreases as the distance from the machine swing

Figure 90

centerline is increased.

Lifting Unknown Weight

When loads are not accurately known are to be lifted, the person

responsible for the job shall ascertain that the weight of the load

FRONT LIFT

does not exceed the machine LOAD RATING CHART at the

ZONE

radius at which it is to be lifted.

It is recommended that you feel your way into any lift as a

precaution against tip-over. One method is to position the boom

at 90° over the side of the machine. Slowly lift the load until it

SIDE LIFT

clears the ground. A lift over the side is the most unstable, and

ZONE

as the load is swung into the front zone of the excavator it will

become more stable. DO NOT INCREASE SWING RADIUS

AFTER THE LOAD IS LIFTED.

REAR LIFT

ZONE

DANGER

HAAD3842

If a load is picked up from the front zone and swung into the

Figure 91

side zone, a tip-over could result causing a deadly or fatal

injury.

Operation

OP001173

3-41

Lifting Known Weight

The load chart is the governing factor when lifting known

weights. It is recommended that you feel your way into any lift as

a precaution against tip-over. Whenever possible, lift and swing

payloads between the front idler area.

Pick and Carry

The machine can pick and carry payloads without added labor.

We recommend when traveling with a suspended payload, you

evaluate the prevailing conditions and determine the safety

precautions required in each case. The following factors must be

considered before attempting to pick and carry a load.

Align the boom with the forward direction of machine travel.

Maintain this boom position when turning the machine. Turn only

when necessary, at the slowest speed, and at a wide turning

radius.

Use the shortest lifting radius distance possible.

Keep the load as close to the ground as conditions will

permit.

Provide tag lines to prevent load from pendulating.

Pendulating can cause a change in radius. A change in

radius could exceed the load chart rating or cause a tip

over condition.

Govern travel speed to suit conditions.

Avoid sudden starts and stops.

Operation

OP001173

3-42

OPERATION UNDER UNUSUAL

CONDITIONS

NOTE: See

“Maintenance in Special Conditions” on

page 4-89 for other recommendations.

Operation In Extreme Cold

If machine is to be operated in extreme cold weather

temperatures, certain precautions must be taken to assure

continued normal operation. The following paragraphs detail

checks to be made to be certain the machine is capable of

operating at these temperatures.

Check the cooling system for correct antifreeze solution for

lowest temperature expected. Carefully inspect cooling

system and correct or report any leaks.

Keep batteries fully charged to prevent freezing. If water is

added to batteries, run engine at least one hour to mix

electrolyte solution.

Keep engine in best possible mechanical condition to

assure easy starting and good performance during

adverse weather.

Use engine oil of the proper specifications for the expected

temperatures. Refer to the "Lubrication Specifications" of

the engine manual for details.

Keep fuel tank full at all times. Drain condensation from

tank before and after operation. Drain and service fuel

filter. To eliminate clogging of fuel filters because of wax

crystal formation in the fuel, be sure that fuel used has a

cloud point specification below the lowest expected

temperature.

Lubricate entire machine according to "Periodic Service

Table and Chart" Section 4, in this manual or lubrication

chart on machine.

Start engine and allow it to reach normal operating

temperature before applying load.

A. If mud and ice collects and freezes on any of the

moving parts while machine is idle, apply heat to

thaw the frozen material before attempting to operate

machine.

B. Operate hydraulic units with care until they have

reached a temperature to enable them to operate

normally.

C. Check all machine controls and/or functions to be

sure they are operating correctly.

An extra outer air filter should be kept in the operator's

cabin to replace element that could become iced and

cause restricted air flow to engine.

If cold weather starting aid must be used, see "Engine

Starting" COLD WEATHER START portion of this manual.

10.

Clean off all mud, snow and ice to prevent freezing. Cover

machine with tarpaulin if possible, keep ends of tarpaulin

from freezing to ground.

Operation

OP001173

3-43

Operation in Extreme Heat

Continuous operation of the machine in high temperatures may

cause the machine to overheat. Monitor engine and

transmission temperatures and stop machine for a cooling-off

period whenever necessary.

Make frequent inspections and services of the fan and

radiator. Check coolant level in radiator. Check grills and

radiator fins for accumulation of dust, sand and insects

which could block the cooling passages.

A. Formation of scale and rust in cooling system occurs

more rapidly in extremely high temperatures. Change

antifreeze each year to keep corrosion inhibitor at full

strength.

B. If necessary, flush cooling system periodically to

keep passage clear. Avoid use of water with a high

alkali content which increases scale and rust formation.

Check level of battery electrolyte daily. Keep electrolyte

above plates preventing damage to batteries. Use a slightly

weaker electrolyte solution in hot climates. Dilute

1.28

specific gravity electrolyte as issued to 1.20 - 1.24 specific

gravity readings at full charge. Recharge batteries whenever

they reach a

1.16 specific gravity reading. Batteries

self-discharge at a higher rate if left standing for long

periods at high temperatures. If machine is to stand for

several days, remove batteries and store in a cool place.

WARNING

Do not store acid type storage batteries near stacks of

tires; the acid fumes have a harmful affect on rubber.

Service fuel system as directed in "Engine Fuel System"

Section 5, of this manual. Check for water content before

filling fuel tank. High temperatures and cooling off cause

condensation in storage drums.

Lubricate as specified in "Periodic Service Chart and

Table" Section 4, in this manual or Lubrication Decal on

the machine.

Do not park machine in sun for long periods of time. When

practical park machine under cover to protect it from sun,

dirt and dust.

A. Cover inactive machine with tarpaulin if no suitable

shelter is available. Protect engine compartment,

transmission and hydraulics from entrance of dust.

B. In hot, damp, climates corrosive action will occur on all

parts of the machine and will be accelerated during

the rainy season. Rust and paint blisters will appear

on metal surfaces and fungus growth on other surfaces.

C. Protect all unfinished, exposed surfaces with a film of

preservative lubricating oil. Protect cables and

terminals with ignition insulation compound. Apply

paint or suitable rust preventive to damaged surfaces

to protect them from rust and corrosion.

Operation

OP001173

3-44

Operation in Dusty or Sandy Areas

Operation of the machine can cause dust in almost any area.

However, when in predominantly dusty or sandy areas,

additional precautions must be taken.

Keep cooling system fins and cooling areas clean. Blow

out with compressed air, if possible, as often as necessary.

WARNING

Wear goggles when using compressed air.

Use care when servicing fuel system to prevent dust and

sand from entering the tank.

Service the air cleaner at frequent intervals, check air

restriction indicator daily and keep dust cup and dust valve

clean. Prevent dust and sand from entering engine parts

and compartments as much as possible.

Lubricate and perform services outlined on current

lubrication chart on machine and "Lubrication Chart and

Table" Section

4. Clean all lubrication fittings before

applying lubricant. Sand mixed with lubricant becomes

very abrasive and speeds wear on parts.

Protect machine from dust and sand as much as possible.

Park machine under cover or protect with tarpaulin to keep

dust and sand from damaging unit.

Operation in Rainy or Humid Conditions

Operation under rainy conditions is similar to that as in extreme

heat procedures listed previously.

Keep all exposed surfaces coated with preservative

lubricating oil. Pay particular attention to damaged or

unpainted surfaces. Cover all paint cracks and chip marks

as soon as possible to prevent corrosive effects.

Operation in Salt Water Areas

The corrosive effect of salt water and salt water spray is very

extensive. When operating in salt water areas, observe the

following precautions.

When exposed to salt water, dry machine thoroughly and

rinse with fresh water as soon as possible.

Keep all exposed surfaces coated with preservative

lubricating oil. Pay particular attention to damaged paint

surfaces.

Keep all painted surfaces in good repair.

Lubricate machine as prescribed on lubrication chart on

machine or "Periodic Service Table and Chart" Section 4,

in this manual. Shorten lubricating intervals for parts

subject to exposure to salt water, if found necessary.

Operation

OP001173

3-45

OP001141

4Inspection, Maintenance

and Adjustment

PREVENTIVE MAINTENANCE

Routine maintenance and inspections are required to keep your

machine in the correct operating condition. The following pages

list the inspection intervals, the system or component checks,

and location references.

NOTE: The following pages list the service checks and their

required intervals. The service cycles may need to be

shortened depending on the working conditions.

Extremely hot or dusty conditions will require more

frequent service. Operational hours are determined

by the amount of time accumulated on the engine

hour meter on the control console in the cabin.

HAOA601L

Figure 1

NOTE: Besides the normal hour meter, the multifunction

gauge can be used to keep track of the hours on

individual filters. See “Filter / Oil Info” on page 2-39.

FG013662

Figure 2

Inspection, Maintenance and Adjustment

OP001141

4-1

Product Identification Number (PIN)

Location

A PIN number, is stamped on the upper frame, under the boom

foot (Figure 3). It is also stamped on the product identification

plate (Figure 4) on outside of the cabin on right.

NOTE: Please make note of these numbers and their

locations. These will be required whenever warranty

or service work is requested. Keep this number on

file, incase the machine is stolen.

FG001447

Figure 3

Doosan Infracore Co., Ltd.

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

Incheon, Korea

FG012987

Figure 4

Component Serial Numbers

There are many serial numbers on each traceable components

of the machine. For example, the engine serial number is

stamped on the rear left side of the engine block, above the

starter. Additional engine information is described on a label

(Figure 5) on the rocker cover.

Please make note of these numbers and their locations. These

will be required whenever warranty service work is requested.

FG000418

Figure 5

Inspection, Maintenance and Adjustment

OP001141

4-2

Safety Precautions

Make sure to lock out the hydraulic controls and post a

notice (Warning Tag) that the machine is being serviced to

prevent any unauthorized operation.

Make sure to clean up any fluid spills, especially around

the engine.

Inspect all fuel lines to make sure that fittings, lines, filters

and O-rings, etc., are tight and are not showing signs of

wear or damage.

If the inspection or test procedure requires that the engine

be running, make sure to keep all unauthorized personnel

away from the machine, and that all industry standard

safety precautions are followed.

Inspection, Maintenance and Adjustment

OP001141

4-3

PRELIMINARY WORK MACHINE

SETUP FOR MAINTENANCE

When performing maintenance specified in this manual, always

park the excavator as follows.

NOTE: Certain types of maintenance may require the

machine to be positioned differently. Always return

machine to this position.

Park on firm, level ground.

Lower bucket to ground.

FG000111

Figure 6

Set safety lever on "LOCK" position.

Unlock

Lock

FG015867

Figure 7

Allow engine to run at low idle for a minimum of five

minutes to allow engine to cool. If this is not done, heat

surge may occur.

HAOB290L

Figure 8

Inspection, Maintenance and Adjustment

OP001141

4-4

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

Reservoir

-22

-4

104

122 °F

Fluid

-30

-20

-10

50 °C

SAE 10W-30

Engine Oil

* SAE 10W-40

Pan

Engine Oil

SAE 15W-40

Swing

SAE 90 and API GL5

Drive Case

Gear Oil

* SAE 80W-90 and API GL5

Final Drive

Case

SAE 140 and API GL5

ISO VG 32

***

Hydraulic

* ISO VG 46

Oil Tank

Oil

ISO VG 68

* ASTM D975 No. 2

Fuel Tank

Diesel Fuel

ASTM D975 No. 1

Grease

* Multipurpose Lithium Grease NLGI No. 2

Fitting

Inspection, Maintenance and Adjustment

OP001141

4-6

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

judgement in selecting lubricant types that are appropriate

for climate conditions.

Inspection, Maintenance and Adjustment

OP001141

4-7

FLUID CAPACITIES

Component

Capacity

36 liters

Oil Pan with Filter

(9.5 U.S. gal.)

Engine

35 liters

Cooling System

(9.2 U.S. gal.)

500 liters

Fuel Tank

(132 U.S. gal.)

160 liters

Tank Level

(42 U.S. gal.)

Hydraulic Oil

280 liters

System

(74 U.S. gal.)

7 liters

Travel Reduction Device (Each)

(1.8 U.S. gal.)

6 liters

Swing Device

(1.6 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

Coolant

Gear Oil (Swing Device, Travel Device)

Air Cleaner Element

Engine Oil

Fuel Filter

Engine Oil Filter

Air Conditioner Filter

Hydraulic Oil

Drain Water

Hydraulic Oil Return Filter

Fuel Cap Filter

Hydraulic Oil Tank Breather

Inspection, Maintenance and Adjustment

OP001141

4-8

SERVICE DATA

DX300LC

No.

Items to Check

Service

Qty.

Service Interval

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

6ℓ

(80W90)

Track Spring

Grease

W10

Gear Oil

Travel Reduction Device

2X7ℓ

F, V

(80W90)

Engine Oil

36ℓ

(10W40)

Hydraulic Oil Tank

Hydraulic Oil

280ℓ

Fuel Tank

Diesel

500ℓ

Fuel Prefilter

Cartridge

Coolant

Radiator

35ℓ

(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

Element

Fuel Cap Filter

Element

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 4-77, for further explanation.

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

“Engine Cooling System” on page 4-77, for further explanation.

: Replacement On Every Interval.

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

Inspection, Maintenance and Adjustment

OP001141

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

4-20

Check Level of Window Washer Liquid

4-21

Inspect Bucket Teeth and Side Cutters for Signs of Wear

4-21

Inspect Engine Fan Blade

4-21

Check Air Intake System

4-22

Inspect Seat Belt for Proper Operation

4-22

Inspect Structure for Cracks and Faulty Welds

4-22

Check Operation of All Switches

4-22

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

4-23

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

4-23

Operating Temperature. Listen for Any Abnormal Sounds

Check Operation of All Controls

4-23

50 Hour / Weekly Service

Perform All Daily Service Checks

4-24

Grease Arm and Bucket Joint Pins

4-24

Grease Swing Bearing

4-25

Drain Water and Sediment from Fuel Tank

4-26

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

4-26

Change Engine Oil and Filter (After First 50 Hours)

4-26

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

4-26

(Links, Shoes, Rollers, Idlers)

250 Hour / Monthly Service

Perform All Daily and 50 Hour Service Checks

4-27

Grease Boom and Arm Joint Pins

4-27

Check Engine Fan Belt Tension

4-29

Check Engine Fan Belt Wear

4-30

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

4-31

Change Breaker Filter Element (Optional)

4-32

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

4-32

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

4-32

Replace Hydraulic Oil Return Filter (After First 250 Hours)

4-33

Change Pilot Filter (After First 250 Hours)

4-33

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

4-33

Inspection, Maintenance and Adjustment

OP001141

4-12

SERVICE ITEM

PAGE

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

Change Fuel Cap Filter

4-49

2,000 Hour / Yearly Service

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

4-51

Change Swing Reduction Device Oil

4-51

Replace Outer and Inner Air Cleaner Elements

4-52

Change Radiator Coolant

4-53

Hydraulic Oil Exchange and Suction Strainer Cleaning

4-55

Check Alternator and Starter**

4-57

Check All Rubber Antivibration Shock Mounts

4-57

Perform and Record Results of Cycle Time Tests

4-57

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

4-57

Check, Adjust Valve Clearance **

4-57

Check Head Bolt Torques

4-57

4,000 Hour / Biennial Service

Major Parts - Periodic Replacement

4-58

12,000 Hour / 6 Year Service

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

4-59

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

Inspection, Maintenance and Adjustment

OP001141

4-13

10 HOUR / DAILY SERVICE

Grease Boom, Arm and Front Attachment

Pins (for first 100 hours)

WARNING

Do not remove grease fitting until pressure is entirely bleed

off by loosening grease fitting slowly to avoid fatal wound.

Let anybody never be in the blowing direction.

FG000500

Be careful to any kinds of works for nipples and hydraulic

Figure 12

line plugs.

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

hours thereafter (See page 4-24).

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.

FG000330

Shut down engine and wait for fifteen minutes. This will

Figure 13

allow all oil to drain back to oil pan.

Remove dipstick (1, Figure 13) 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 13), if the oil

level is below the "LOW" mark.

FG000616

Figure 14

Inspection, Maintenance and Adjustment

OP001141

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 15

fill cap or service covers.

Park machine on firm, level ground. Lower boom and

position bucket on ground as shown in Figure 16.

Set engine speed to "LOW IDLE."

FG000012

Figure 16

Set safety lever to "LOCK" position.

Check level gauge by opening right access door. Oil level

must be between marks on sight gauge.

FG000118

Figure 17

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

A. Shut down engine.

B. The hydraulic tank is pressurized. Lift the breather

cap slowly to allow the pressurized air to vent.

C. Remove upper cover of the hydraulic tank and add

oil.

IMPORTANT

FG000127

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

Figure 18

can result in damage to equipment and oil leaking

from hydraulic tank because of expansion.

Inspection, Maintenance and Adjustment

OP001141

4-15

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

A. Shut down engine and wait for the hydraulic oil to

cool down.

B. Drain the excess oil from drain plug (Figure 19) 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.

FG014339

Figure 19

Check for Leaks in Hydraulic System

Perform a daily walk-around inspection to make sure that

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

OP001141

4-16

Check Fuel Level

WARNING

Use extreme safety precautions while refueling to prevent

explosions or fire.

Immediately clean up any split fuel.

FG000130

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

fill tube (1, Figure 20). When working at a temperature of

Figure 20

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

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

equivalent.

Make sure that 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 20).

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 4-80, for further information.

Do not overfill the tank.

Securely tighten cap after fueling.

NOTE: If breather holes

(3, Figure

21) 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 21

Check for Leaks in Fuel System

Perform an inspection of the engine compartment to verify

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

the source of the leak and repair.

Inspection, Maintenance and Adjustment

OP001141

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 22

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

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

FG002080

Figure 23

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

24) on

bottom of bowl (1).

NOTE: Dispose of drained fluids according to local

regulations.

Close drain valve.

open

FG000438

Figure 24

Inspection, Maintenance and Adjustment

OP001141

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 remove

and wipe it clean before making final level check.

FG000133

Remove dipstick (1, Figure 25) and wipe the oil from the

Figure 25

dipstick with a cloth.

Insert dipstick (1, Figure 25) 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 25).

FG000419

Figure 26

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

the drain plug (3, Figure 27). Drain the excessive oil into a

suitable container.

NOTE: Dispose of drained fluids according to local

regulations.

FG014340

Figure 27

Inspection, Maintenance and Adjustment

OP001141

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.

FG000151

Figure 28

WARNING

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

sure that proper eye protection is worn.

Loosen the wing bolt(s) and remove dust net.

Clean with compressed air or water.

Check Cooling System and Refill As

Required

WARNING

FULL

Allow the engine to cool before releasing the radiator cap.

LOW

Make sure to loosen the cap slowly to release any

remaining pressure.

Radiator cleaning is performed while the engine is running.

FG000136

Take extreme caution when working on or near a running

Figure 29

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

personnel that service work is being performed.

Do not remove 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 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

4-79)

Check to make sure that 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

"FULL" and "LOW" marks on tank.

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

tank.

Inspection, Maintenance and Adjustment

OP001141

4-20

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 30

Inspect Bucket Teeth and Side Cutters for

Signs of Wear

Daily, 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 bucket adapter is exposed. See Figure 31.

NOTE: These instructions are only for DOOSAN OEM

buckets. If you are using other manufacturers'

buckets, refer to their specific instructions.

Figure 31 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 32

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

OP001141

4-21

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

FG000421

on air intake system.

Figure 34

Inspect Seat Belt for Proper Operation

Inspect 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 Operation of All Switches

Verify the working condition of all switches before starting

the engine.

Inspection, Maintenance and Adjustment

OP001141

4-22

Check 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"

now.

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 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

OP001141

4-23

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.

D B,E

FG001437

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

OP001141

4-24

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)

FG001438

Figure 36

E. Bucket cylinder rod pin (1 point)

FG001439

Figure 37

Grease Swing Bearing

Park 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.

FG000143

Figure 38

Inspection, Maintenance and Adjustment

OP001141

4-25

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 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 4-29.

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 4-83.

Jack up each track and perform the two speed travel motor

test.

Inspection, Maintenance and Adjustment

OP001141

4-26

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 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

OP001141

4-27

Check Engine Fan Belt Tension

FAN

10mm/10kg

COMPRESSOR

IMPORTANT

A loose fan belt can cause engine overheating, poor

ALTERNATOR

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

can cause damage to the water pump, alternator bearing or

belt.

CRANKSHAFT

FG000353

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

Figure 45

operation.)

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

by pressing downwards on the belt, midway between the

fan pulley and alternator pulley. The belt should flex

approximately 10 mm (0.4 in). See Figure 45. To adjust the

belt, loosen the alternator adjustment plate bolts, adjust the

belt tension and retighten the bolts.

Inspection, Maintenance and Adjustment

OP001141

4-29

Check Engine Fan Belt Wear

WARNING

Keep clear of engine fan and fan drive belts when the

engine is running. Rotating fan and belt contact can cause

injury.

Figure 46

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 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

OP001141

4-30

Check Oil Level in Travel Reduction

Device (One on Each Side of Unit)

WARNING

The gear oil is very hot after the machine has been

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

Before fully removing any motor case inspection port plug,

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

FG000298

escape.

Figure 47

Make sure that machine is on firm, level ground.

Rotate the track until ports (1 thru 3, Figure 47) are in their

proper positions as shown.

Loosen fill plug (3, Figure 47) slightly to allow pressurized

air to escape.

Remove oil level plug (1, Figure 47).

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

level plug opening.

Add oil through the fill plug

(3, Figure

47) opening, if

necessary.

Clean and install oil level and fill plugs (1 and 3, Figure 47).

Repeat this procedure on the other travel reduction device.

Inspection, Maintenance and Adjustment

OP001141

4-31

Change Breaker Filter Element (Optional)

WARNING

The hydraulic oil will be hot after normal machine

operation.

Allow the system to cool down before changing pilot filter.

FG000339

Park machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

Figure 48

Loosen the hydraulic oil tank breather cap to release

pressure.

Locate breaker filter assembly (Figure 48).

Position a container under the filter assembly. Remove the

drain plug and completely drain the assembly.

Using a 30 mm spanner, unscrew filter housing from filter

bottom.

Remove O-ring from filter head.

Replace filter.

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

install the filter housing on the filter head.

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

Install drain plug in bottom of filter housing.

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

level of hydraulic oil tank.

Change Swing Reduction Device Oil (Drain

and Refill After First 250 Hours)

NOTE: Change swing reduction device oil after first

250

hours on a new machine and every 2,000 hours

thereafter (See page 4-51).

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).

Inspection, Maintenance and Adjustment

OP001141

4-32

Replace Hydraulic Oil Return Filter (After

First 250 Hours)

NOTE: Replace hydraulic oil return filter after first 250 hours

of operation or rebuild, then every

1,000 hours

thereafter (See page 4-44).

Change Pilot Filter (After First 250 Hours)

NOTE: Change pilot filter after first 250 hours and every

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

Inspect Pins and Bushings of the Front

End Attachments for Signs of Wear

Check Fluid Levels in Batteries and

Battery Charge Levels

Inspect for Any Loose or Missing Nuts and

Bolts

Inspect Fuel System Hose Clamps

Inspection, Maintenance and Adjustment

OP001141

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.

FG000147

Figure 49

If water or other contaminations are found, remove lower

access cover so the gear teeth can be thoroughly cleaned

and lubricated.

Install access covers after lubricating gear teeth.

FG000148

Figure 50

Inspection, Maintenance and Adjustment

OP001141

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 51) and install hose (2) to drain the engine oil.

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

NOTE: Dispose of drained fluids according to local

regulations.

FG000144

Figure 51

Replace engine oil filter by using filter wrench. The engine

oil filter is a spin-on type. See Figure 52. 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.

FG000145

Figure 52

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

(Figure 53). 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.

FG000146

Figure 53

Inspection, Maintenance and Adjustment

OP001141

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: If 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.

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

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

Open the cover by using the starter KEY in the left side of

the cabin.

FG016043

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.

FG016044

Figure55

Inspection, Maintenance and Adjustment

OP001141

4-36

Check and Clean Air-Conditioning Inner

Filter

WARNING

All service and inspection of air-conditioning system

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

(OFF) position.

WARNING

If using compressed air to clean the element, make sure

that proper eye protection is worn.

FG016045

Remove the filter by pulling out ward the knob while

Figure 56

pressing the upper part and lower part of the filter handle

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

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

damaged replaced by a new one.

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

water to clean it.

IMPORTANT

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

completely dry before installing.

Inspection, Maintenance and Adjustment

OP001141

4-37

Clean Radiator, Oil Cooler, Intercooler,

Fuel Cooler and Air Conditioner

Condenser Core

WARNING

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

there is danger of injury. Always wear protective glasses,

FG000150

mask and safety shoes during the cleaning precess. Make

Figure 57

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

Open the rear left door and engine cover.

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

of oil cooler and intercooler.

FG000151

Figure 58

Remove wing bolts and plate (Figure 59) between radiator

and oil cooler.

Clean the outside of the radiator and oil cooler, intercooler

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

from the outside of the engine compartment inwards.

Repeat the cleaning process from the inside of the engine

compartment outwards to remove all dirt and debris.

NOTE: Clean dust net and install it after cleaning

radiator, oil cooler, intercooler and fuel cooler.

FG000152

Figure 59

Clean air conditioner condenser core with compressed air,

steam or water.

IMPORTANT

To prevent damage to the cores, apply compressed air

from an appropriated distance. Damaged core may

cause water leakage or overheating. In a dusty site,

check the core daily, irrespective of the maintenance

interval.

FG000153

Figure 60

Inspection, Maintenance and Adjustment

OP001141

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 61)

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 61

WARNING

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

engine is running.

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

proper eye protection is worn.

Locate the air cleaner assembly.

NOTE: When it reaches every 500 hours or If indicator

light

(Figure

61) on instrument panel comes

"ON" the air cleaner must be serviced.

NOTE: Replace outer filter after cleaning 5 times or

every 2,000 hours / 1 year of service.

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

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

lips for wear or damage. Replace valve if necessary.

FG000297

NOTE: Install evacuator valve with lips parallel to the

Figure 62

cover.

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

latches (3).

Remove outer filter (4, Figure 63) from the housing. Do not

remove inner filter (5).

FG000702

Figure 63

Inspection, Maintenance and Adjustment

OP001141

4-39

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

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

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

HAOC570L

Figure 64

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

holes or thinner parts are found on the element after

cleaning it, replace the filter.

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

the air cleaner cover. Do not use compressed air.

Properly install the air filter and cover.

After filter service be sure to install cover with arrows

pointing "UP."

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

FG000412

clogged indicator remains "ON," replace the

Figure 65

outer and inner filters. Do not clean inner filter.

Inspection, Maintenance and Adjustment

OP001141

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.

FG000413

Figure 66

Remove bowl using supplied tool.

Remove cartridge.

FG000436

Figure 67

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

cartridge (1).

Tighten the cartridge by hand until the packing comes into

contact with the surface of the filter housing head.

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

of a turn more.

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

the bowl with tool.

FG000428

Figure 68

Inspection, Maintenance and Adjustment

OP001141

4-41

Change Fuel Filter

WARNING

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

fire hazards. Do not smoke.

Locate fuel filter inside engine compartment.

FG000154

Position a small container under fuel filter.

Figure 69

Unscrew fuel filter from head assembly. Discard fuel filter.

NOTE: Dispose of drained fluids according to local

regulations.

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

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

more with a filter wrench.

NOTE: Coat fuel filter gasket with fuel.

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

reduce fuel system priming.

FG000478

Figure 70

Fuel System Priming

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

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

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

engine speeds.

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

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

procedure:

Shut down engine.

FG000431

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

Figure 71

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

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

in fuel prefilter head.

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

Continue to pump primer pump until a strong resistance is

felt.

Start engine and look for signs of leaks.

Repeat procedure if necessary.

Inspection, Maintenance and Adjustment

OP001141

4-42

1,000 HOUR / 6 MONTH SERVICE

Perform All Daily, 50, 250 and 500 Hour

Service Checks

Grease Swing Reduction Device

Park machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

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

device.

FG000439

Figure 72

Press grease fitting and inject grease with the grease gun

on the marked point (2, Figure 73).

Install air vent plug

(1, Figure

72) in swing reduction

device.

FG000156

Figure 73

Inspection, Maintenance and Adjustment

OP001141

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 74) on

instrument panel comes "ON" the return filter must be

serviced.

FG013832

Figure 74

WARNING

The hydraulic oil will be hot after normal machine

operation. Allow the system to cool before attempting to

service any of the hydraulic components.

The hydraulic tank is pressurized. Lift the hydraulic

breather cap slightly to allow the pressurized air to vent.

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

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

FG000424

tank.

Figure 75

IMPORTANT

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

hydraulic tank, especially around the fill port and filter

ports.

Park machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

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

internal pressure.

Remove bolts

(2, Figure

75) and service cover

(3).

Remove spring (4), valve

(5) O-ring

(6), and bypass

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

Remove filter and discard.

NOTE: Used filter should always be disposed of

according to local regulations.

FG000761

Figure 76

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

valve and spring. Install service cover plate.

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

circuit.

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

necessary.

Inspection, Maintenance and Adjustment

OP001141

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

77) on

instrument panel comes "ON" the pilot filter must be

serviced.

FG013895

Figure 77

WARNING

The hydraulic oil will be hot after normal machine

operation.

Allow the system to cool down before changing pilot filter.

Park machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

FG000149

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

Figure 78

internal pressure.

Locate pilot system filter assembly. See Figure 78.

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

filter cartridge (4).

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

when removing this assembly.

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

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

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

NOTE: Used filter should always be disposed of

according to local regulations.

FG000323

After changing pilot filter, vent air from pump and check

Figure 79

level of hydraulic oil tank.

Inspection, Maintenance and Adjustment

OP001141

4-45

Change Oil in Travel Reduction Device

(One on Each Side of Unit)

WARNING

The gear oil is very hot after the machine has been

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

Before fully removing any motor case, inspection port plug,

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

FG000298

escape.

Figure 80

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

and every 1,000 hours thereafter.

Make sure that machine is on firm, level ground.

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

proper positions as shown.

Place a container under drain plug (2, Figure

80) and

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

oil.

NOTE: Dispose of drained fluids according to local

regulations.

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

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

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

NOTE: See

“Fluid Capacities” on page 4-8. for

capacity.

Repeat this procedure on the other travel reduction device.

Change Air Breather Filter

Park machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.

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

internal pressure.

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

cap (2, Figure 81).

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

breather cap by tighting the bolt.

NOTE: Used filter should always be disposed of

according to local regulations.

FG013207

Figure 81

Inspection, Maintenance and Adjustment

OP001141

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 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.

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

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

Open the cover by using the starter KEY in the left side of

the cabin.

FG016043

Figure 82

Remove filter (Figure 83) and replace with new one.

Reassemble in reverse order.

FG016044

Figure83

Inspection, Maintenance and Adjustment

OP001141

4-47

Check Air Conditioner Refrigerant

WARNING

Mixing of tobacco smoke and freon is deadly.

Do not smoke while servicing or recharging

air-conditioning system.

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

FG000157

ten minutes to stabilize the system.

Figure 84

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

OP001141

4-48

2,000 HOUR / YEARLY SERVICE

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

Hour Service Checks

Change Swing Reduction Device Oil

NOTE: Change swing reduction device oil after first

250

hours of operation or rebuild and every 2,000 hours

thereafter.

WARNING

The gear oil is very hot after the machine has been

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

FG000133

Figure 91

Set a container under excavator.

Release the drain plug (3, Figure 92) and drain the swing

reduction device oil into a container.

NOTE: Dispose of drained fluids according to local

regulations.

After draining oil, tighten the drain plug.

FG014340

Figure 92

Remove breather/fill cap (2, Figure 91) and add oil to "H"

mark on dipstick (1).

FG000419

Figure 93

Inspection, Maintenance and Adjustment

OP001141

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

FG000414

2,000 hours of service.

Figure 94

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 95) 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 95

Remove outer filter (4, Figure 95) from the air cleaner

housing.

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

housing.

Remove inner filter (5, Figure 96).

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 96

Inspection, Maintenance and Adjustment

OP001141

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 97

personnel that service work is being performed.

Do not remove 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 98).

NOTE: Dispose of drained fluids according to local

regulations.

FG000319

Figure 98

Inspection, Maintenance and Adjustment

OP001141

4-53

Remove coolant drain plug (1, Figure 99) from engine.

Install drain plug, and close drain valve after coolant has

completely drained from system.

Fill cooling system with a flushing solution.

Run engine at low idle until the coolant temperature gauge

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

minutes.

Allow engine to cool.

Drain flushing fluid and fill system with water.

FG000322

Figure 99

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 4-79.

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

purged from system. Fill radiator to fill neck.

12. Drain and fill radiator coolant recovery tank.

Inspection, Maintenance and Adjustment

OP001141

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.

Park 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).

FG000356

Figure 101

Inspection, Maintenance and Adjustment

OP001141

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

disposed of according to local regulations.

FG014339

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 612.5 mm (24.11 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 4-85.

IMPORTANT

When the hydraulic breaker is being used, because of

the higher heat generated by this unit, use

replacement intervals recommended under the

“Hydraulic Oil and Filter Service Intervals” on

page 3-37.

13.

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

ARO1720L

Figure 104

Inspection, Maintenance and Adjustment

OP001141

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 (Tank to CP pump)

Heater hose (Heater to engine)

Heater hose (Heater to radiator)

Air Conditioner hose

Hydraulic

Body

Pump suction hose

2 years or 4,000 hours

System

Pump discharge hoses

Pump side branch hoses

Swing motor hoses

Travel motor hoses

Work

Boom cylinder line hoses

Device

Arm cylinder line hoses

Bucket cylinder line hoses

Inspection, Maintenance and Adjustment

OP001141

4-58

Doosan DX300LC. Operation and Maintenance Manual (2010) - page 3