Doosan DX300LC. Operation and Maintenance Manual (2010) - page 4
12,000 HOUR / 6 YEAR SERVICE
Hose In-service Lifetime Limit (European
Standard ISO 8331 and EN982 CEN)
European regulations state that 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
OP001141
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 4-29.
Inspection, Maintenance and Adjustment
OP001141
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
BOLT
NO.
POINT TO BE INSPECTED
QTY.
HEAD
DIA. mm
kg•m
Nm
ft lb
SIZE
Joint bolt with engine mounting
pump side
16
8
24
24.5
240
177
1
bracket and engine
fan side
12
8
19
11.2
110
81
Joint bolt and nut between engine
pump side
20
2
30
46
451
333
2
mounting bracket and frame
fan side
20
2
30
46
451
333
3
Radiator mounting bolt
20
4
30
55
539
398
4
Tightening bolt for hydraulic oil tank
16
6
24
27
265
195
5
Tightening bolt for fuel tank
16
6
24
27
265
195
6
Tightening bolt for pump
20
4
17 (S)
49
480
354
7
Tightening bolt for control valve
16
4
24
27
265
195
8
Tightening bolt for swing reduction device
24
12
36
95
931
687
9
Tightening bolt for swing motor
12
16
10 (S)
11
108
80
10
Tightening bolt for battery
10
2
17
5
49
36
Joint bolt with cabin mounting rubber and
10
20
17
6.5
64
47
frame
11
Joint bolt with cabin mounting rubber and
16
5
24
21
206
152
cabin
Joint bolt with swing bearing and upper
24
35
36
95
931
687
frame
12
Joint bolt with swing bearing and bottom
24
36
36
95
931
687
frame
Tightening bolt for travel device
20
40
30
49
480
354
13
Tightening bolt for sprocket
20
48
30
49
480
354
14
Tightening bolt for upper roller
20
4
30
55
539
398
15
Tightening bolt for bottom roller
20
72
30
55
539
398
16
Tightening bolt for track guard
20
16
30
55
539
398
17
Bolt for track shoes
22
384
37
115
1127
832
18
Fixing bolt for front pin
16
10
24
27
265
195
19
Breaker Filter (Optional)
1
30
27
265
195
20
Grease valve for track adjuster
PF 1/2
2
27
14
137
101
39X3
21
Mounting bolt for the ROPS
1
60
250
2450
1807
(Thin Screw)
Inspection, Maintenance and Adjustment
OP001141
4-61
1.
Joint bolt with engine mounting bracket and engine
1) Pump side
•
Tool: 24 mm (
)
•
Torque: 24.5 kg•m (240 Nm, 177 ft lb)
FG000442
Figure 105
2) Fan side
•
Tool: 19 mm (
)
•
Torque: 11.2 kg•m (110 Nm, 81 ft lb)
FG000443
Figure 106
2.
Joint bolt and nut between engine mounting bracket and
frame
1) Pump side
•
Tool: 30 mm (
)
•
Torque: 46 kg•m (451 Nm, 333 ft lb)
FG000444
Figure 107
2) Fan side
•
Tool: 30 mm (
)
•
Torque: 46 kg•m (451 Nm, 333 ft lb)
FG000445
Figure 108
Inspection, Maintenance and Adjustment
OP001141
4-62
3.
Radiator mounting bolt
•
Tool: 30 mm (
)
•
Torque: 55 kg•m (539 Nm, 398 ft lb)
FG000446
Figure 109
4.
Tightening bolt for hydraulic oil tank
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG000447
Figure 110
5.
Tightening bolt for fuel tank
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG000448
Figure 111
6.
Tightening bolt for pump
•
Tool: 17 mm (
)
•
Torque: 49 kg•m (480 Nm, 354 ft lb)
FG000449
Figure 112
Inspection, Maintenance and Adjustment
OP001141
4-63
7.
Tightening bolt for control valve
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG000450
Figure 113
8.
Tightening bolt for swing reduction device
•
Tool: 36 mm (
)
•
Torque: 95 kg•m (931 Nm, 687 ft lb)
FG000451
Figure 114
9.
Tightening bolt for swing motor
•
Tool: 10 mm (
)
•
Torque: 11 kg•m (108 Nm, 80 ft lb)
FG000452
Figure 115
10. Tightening bolt for battery
•
Tool: 17 mm (
)
•
Torque: 5 kg•m (49 Nm, 36 ft lb)
FG000453
Figure 116
Inspection, Maintenance and Adjustment
OP001141
4-64
11. Joint bolt with cabin mounting rubber and frame
•
Tool: 17 mm (
)
•
Torque: 6.5 kg•m (64 Nm, 47 ft lb)
FG000454
Figure 117
Joint bolt with cabin mounting rubber and cabin
•
Tool: 24 mm (
)
•
Torque: 21 kg•m (206 Nm, 152 ft lb)
FG000455
Figure 118
12. Joint bolt with swing bearing and upper frame
•
Tool: 36 mm (
)
•
Torque: 95 kg•m (931 Nm, 687 ft lb)
FG000456
Figure 119
Joint bolt with swing bearing and bottom frame
•
Tool: 36 mm (
)
•
Torque: 95 kg•m (931 Nm, 687 ft lb)
FG000457
Figure 120
Inspection, Maintenance and Adjustment
OP001141
4-65
13. Tightening bolt for travel device
•
Tool: 30 mm (
)
•
Torque: 49 kg•m (480 Nm, 354 ft lb)
FG000458
Figure 121
Tightening bolt for sprocket
•
Tool: 30 mm (
)
•
Torque: 49 kg•m (480 Nm, 354 ft lb)
FG000459
Figure 122
14. Tightening bolt for upper roller
•
Tool: 30 mm (
)
•
Torque: 55 kg•m (539 Nm, 398 ft lb)
FG000460
Figure 123
15. Tightening bolt for bottom roller
•
Tool: 30 mm (
)
•
Torque: 55 kg•m (539 Nm, 398 ft lb)
FG000461
Figure 124
Inspection, Maintenance and Adjustment
OP001141
4-66
16. Tightening bolt for track guard
•
Tool: 30 mm (
)
•
Torque: 55 kg•m (539 Nm, 398 ft lb)
FG000462
Figure 125
17. Bolt for track shoes
Tighten the bolts in the order as shown in the Figure 126 (1
→ 4)
•
Tool: 37 mm (
)
4
•
Torque: 115 kg•m (127 Nm, 832 ft lb)
2
1
3
FG014337
Figure 126
18. Fixing bolt for front pin
•
Tool: 24 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG000464
Figure 127
Inspection, Maintenance and Adjustment
OP001141
4-67
19. Fixing breaker filter (Optional)
•
Tool: 30 mm (
)
•
Torque: 27 kg•m (265 Nm, 195 ft lb)
FG000339
Figure 128
20. Grease valve for track adjuster
•
Tool: 27 mm (
)
2
•
Torque: 14 kg•m (137 Nm, 101 ft lb)
1
3
FG000163
Figure 129
21. Mounting bolt for the ROPS
•
Tool: 60 mm (
)
•
Torque: 250 kg•m (2450 Nm, 1807 ft lb)
FG016028
Figure 130
Inspection, Maintenance and Adjustment
OP001141
4-68
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 131
1.
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 131.
2.
To replace a tooth (1, Figure 132), use a hammer and
punch to drive locking pin (2) and lock washer (3) out of
tooth adapter (4).
4
3.
Once worn tooth has been removed, use a putty knife to
3
scrape adapter as clean as possible.
2
4.
Slide new tooth into position and insert lock washer.
1
FG000346
Figure 132
5.
Insert locking pin into tooth and with a hammer, drive pin in
until lock washer seats in locking groove.
Inspection, Maintenance and Adjustment
OP001141
4-69
Bucket O-ring Replacement
WARNING
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
1.
Inspect bucket O-rings on a routine basis. If worn or
FG000502
damaged, replacement is necessary.
Figure 133
2.
Roll old O-ring (1, Figure 134) onto boss (2) around bucket
pin (3). Remove bucket pin and move arm or bucket link
1
4
(4) out of way.
2
3
ARO1390L
Figure 134
3.
Remove old O-ring and temporarily install new O-ring (1,
Figure 135) onto bucket boss (2). Make sure that O-ring
1
4
groove on both bucket link
(4) and boss have been
2
cleaned.
4.
Realign arm or link with bucket pin hole and insert bucket
pin (3, Figure 134).
ARO1391L
Figure 135
5.
Roll new O-ring (1, Figure 136) into O-ring groove.
1
ARO1392L
Figure 136
Inspection, Maintenance and Adjustment
OP001141
4-70
BUCKET SHIMMING
PROCEDURES
New Bucket Installation
1.
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.
2.
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.
Inspection, Maintenance and Adjustment
OP001141
4-71
Shimming Procedures for Installed Bucket
3
1
2
8
7
5
10
9
4
6
FG000415
Figure 137
Reference
Reference
Description
Description
Number
Number
1
No Clearance
6
Plate
2
Arm
7
Bolt
3
Bucket Clearance
8
Hard Washer
4
Shim
9
Flange
5
Pin
10
Bucket Boss
1.
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.
2.
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 (3, Figure 137). 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.
3.
Recheck end play by forcing bucket towards opposite side
and repeating clearance measurements.
4.
If an adjustment is required, detach stopper (6, Figure 137)
and bolts (7, Figure 137). Add or remove shims (4, Figure
137) as required. Use shims (4, Figure 137) on one side.
Tighten bolts with torque (27 kg•m) (7, Figure 137).
Inspection, Maintenance and Adjustment
OP001141
4-72
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 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
OP001141
4-73
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 138
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 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.
HAOU790L
Figure 139
Battery Replacement
When the charging indicator indicates transparency state,
replace the battery. The batteries should always be replaced in
pairs.
Using an old battery with a new one will shorten the life span of
the new battery.
Inspection, Maintenance and Adjustment
OP001141
4-74
Fuses
1.
The fuses in the fuse box are used to protect the various
O
X
electrical circuits and their components from being
damaged. See Figure 140. The fuses used are standard
automotive type fuses.
2.
The section on “Fuse Identification” on page 4-76, lists the
circuits and the fuse amperage required for each circuit. If
a fuse blows, determine the cause and repair any faults or
failures.
HAOC670L
3.
Do not insert a higher amperage fuse into a lower
Figure 140
amperage slot. Serious damage to the electrical
components or fire can result.
CAUTION
Before replacing a fuse, be sure to turn starter switch to "O"
(OFF) position.
Fuse Boxes
There are two fuse boxes (Figure 141) on the left side of the
heater box. The fuses prevent electrical devices from
overloading or shorting.
A decal attached inside 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 141
CAUTION
Always replace fuses with the same type and capacity fuse
that was removed. Otherwise, electrical damage could
result.
Inspection, Maintenance and Adjustment
OP001141
4-75
Fuse Identification
Fuse Box (1)
Fuse Box (2)
FG000542
Figure 142
Fuse Box One
Fuse Box Two
No.
No.
Name
Capacity
Name
Capacity
1
Warning Light (Optional)
10A
1
Horn
10A
2
2-pump (Optional)
10A
2
Quick Clamp (Optional)
10A
3
Cigar Lighter
10A
3
Travel Alarm (Optional)
10A
4
12V Power
10A
4
Auxiliary Mode
10A
5
Wiper, Washer
10A
5
Check Connector
10A
6
Lower Wiper (Optional)
10A
6
Pilot Cutoff
10A
7
Stereo
10A
7
Memory Backup
10A
Starter Switch,
8
10A
8
Room Light
10A
Hour Meter
9
Spare
30A
9
Cabin Light (Optional)
30A
10
Air Conditioner, Heater
20A
10
Work Light
20A
11
Shear, Breaker (Optional)
20A
11
Fuel Heater
20A
Instrument Panel, Pressure
12
Seat Heater (Optional)
15A
12
15A
Sensor
e-EPOS, Booster, Travel
13
15A
13
Headlight
15A
speed changer, Booster
14
ECU
15A
14
Fuel Pump (Optional), Wiper
15A
Inspection, Maintenance and Adjustment
OP001141
4-76
ENGINE COOLING SYSTEM
General
Keeping an engine's cooling system in peak operating condition,
can have many benefits to keeping a machine in good operating
condition. A properly functioning cooling system will; improve
fuel efficiency, reduce engine wear, and extend component life.
Always use distilled water in the radiator. Contaminants in tap
water neutralize the corrosion inhibitor components. If tap water
must be used, it should not exceed 300 ppm hardness, or
contain more than 100 ppm of either chloride or sulfate. Water
that has been treated with a water softener also contains salt
that will cause corrosion of components. Water from creeks and
stagnant pools usually contains dirt, minerals and/or organic
material that are deposited in the cooling system and impair
cooling efficiency. Distilled water is the best.
Engine overheating is often caused by bent or clogged radiator
fins. The spaces between the fins can be cleaned by use of air
or water under pressure. When straightening bent fins, use care
not to damage the tubes or break the bond between the fins and
the tubes.
WARNING
Pressure at air nozzle must not exceed 2 bar (30 psi).
Always wear goggles when using compressed air.
Do not pour cold water into radiator when engine is very hot
and water level is below the top of the tubes. Such action
could result in damage to engine cylinder heads.
Heavy duty diesel engines require a balanced mixture of water
and antifreeze. Drain and replace the mixture every year or
2,000 hours of operation, which ever comes first. This will
eliminate buildup of harmful chemicals.
Antifreeze is essential in any climate. It broadens the operating
temperature range by lowering the coolant's freezing point and
by raising its boiling point. Do not use more than 50% antifreeze
in the mixture unless additional freeze protection is required.
Never use more than 68% antifreeze under any condition.
Inspection, Maintenance and Adjustment
OP001141
4-77
Types of Antifreeze
There are two main classifications of antifreeze available on the
market today.
1.
Ethylene Glycol - Doosan Genuine Antifreeze Solution
(for all seasons)
2.
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
OP001141
4-78
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%
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
OP001141
4-79
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
OP001141
4-80
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
1
4
3
2
5
FUEL TANK
FG000161
Figure 143
Reference
Reference
Description
Description
Number
Number
1
Body
4
Strainer Cap
2
Check Valve
5
Inlet Hose
3
Strainer
1.
Remove strainer cap (4, Figure 143) from strainer (3) on
end of inlet hose (5).
NOTE: Keep strainer cap (4, Figure 143) in a safe
location to reseal strainer (3) after refueling is
complete.
I
O
2.
Insert inlet hose (5, Figure 143) into refueling tank.
3.
Turn fuel pump switch (Figure 144) inside of battery box on
front side to "I" (ON) position.
NOTE: Transfer pump rate of flow is approximately
35 lpm (9.24 U.S. gpm). Use extra care not to
FG003379
overfill fuel tank so fuel does not over flow.
Figure 144
4.
Once fuel transfer is completed, immediately turn switch to
"O" (OFF) position to stop pump.
5.
Lift inlet hose (5, Figure 143) from fueling source and turn
switch to "I" (ON) position for two - three seconds to drain
remaining fuel from hose to fuel tank.
6.
Install strainer cap (4, Figure 143) on inlet strainer (3) and
return hose (5) to storage position.
Inspection, Maintenance and Adjustment
OP001141
4-81
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:
1.
Park machine on firm, level ground. Lower the front
attachment to the ground and shut down engine.
2.
Set safety lever on "RELEASED" position.
3.
Turn starter switch to the "I" (ON) position.
4.
Fully stroke work and travel levers in all directions.
5.
Set safety lever on "LOCK" position.
6.
Turn key to "O" (OFF) position and remove from starter
switch.
7.
Remove accumulator by unscrewing it slowly.
FG013208
Figure 145
Inspection, Maintenance and Adjustment
OP001141
4-82
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
track tension grease valve should never be backed off more
than one complete turn from the fully tightened 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.
1.
Track tension is checked by jacking up one side of the
excavator. See Figure 146. Place blocking under frame
while taking measurement.
90 ~ 110
FG000345
Figure 146
2.
Measuring the distance
(A, Figure
147) 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 320 - 340 mm (12.60 - 13.39 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
A
checking clearance.
3.
Too little sag in the crawler track
(less than
320 mm
(12.60 in) clearance) can cause excessive component
FG000162
wear. The recommended adjustment can also be too tight
Figure 147
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
OP001141
4-83
4.
The increased clearance recommended for muddy ground
conditions is between 340 - 370 mm (13.39 - 14.57 in). The
clearance should be approximately 370 mm (14.57 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 track tension grease valve should never be
backed off more than 1 complete turn from the fully
tightened down position. Bleed off pressure slowly
and keep your body away from the valve at all times. If
there is problem in the valve thread, the valve might be
ejected at high speed to cause fatal wound.
5.
Track tension adjustments are made through the grease
fitting
(1, Figure 148) in the middle of each side frame.
2
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.
6.
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
1
hole in valve (3, Figure 148) by loosening valve slowly (3,
3
Figure 148).
FG000163
Figure 148
NOTE: After track tension is adjusted by loosening
valve, be sure to tighten valve (3, Figure 148)
with 14 kg•m (137 Nm, 101 ft lb).
WARNING
Do not loosen or remove the grease fitting (1, Figure
148) until the pressure is entirely bleed off by
loosening valve (3, Figure 148) slowly.
Inspection, Maintenance and Adjustment
OP001141
4-84
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.
1.
With the engine stopped, remove vent plug (Figure 149) to
see if any oil is present.
2.
If oil is not present, fill pump with oil through port (Figure
149).
3.
Install vent plug (Figure 149) first.
FG000158
Figure 149
4.
Start engine and run it for several minutes at low idle
engine speed. This will pressurize the hydraulic oil tank
and system.
5.
Slowly loosen vent plug (Figure 149) several turns, until
hydraulic oil flows out of plug. This shows that air has been
released.
6.
Tighten the plug (Figure 149).
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.
1.
Run engine at low idle. Extend and retract each cylinder to
within 100 mm (4 in) of fully stroking it 4 - 5 times.
2.
Operate fully extend and retract each cylinder 3- 4 times.
3.
Repeat procedure until cylinders extend and retract
smoothly.
Inspection, Maintenance and Adjustment
OP001141
4-85
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.
FG000159
1.
Shut down engine.
Figure 150
2.
Disconnect drain hose and fill swing motor case with
hydraulic oil.
3.
Connect the drain hose.
4.
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
1.
Shut down engine
2.
Disconnect drain hose (Figure 151) and fill motor case with
hydraulic oil.
3.
Connect drain hose.
4.
Start engine and set engine speed control dial to "LOW
FG000160
IDLE." Run the engine for one minute and slowly drive
Figure 151
excavator forwards and backwards.
General Venting
1.
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.
2.
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.
3.
Check for oil leaks and clean all fill and venting locations.
Inspection, Maintenance and Adjustment
OP001141
4-86
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.
FG014341
Check that storage site is not subject to flooding or other natural
Figure 152
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
OP001141
4-87
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
OP001141
4-88
MAINTENANCE IN SPECIAL
CONDITIONS
NOTE: See
“Operation Under Unusual Conditions” on
page 3-43 for other recommendations.
Conditions
Maintenance Required
Operating in mud, water or rain.
Perform a walk around inspection to check for any loose
fittings, obvious damage to the machine or any fluid leakage.
After completing operations, clean mud, rocks or debris from
the machine. Inspect for damage, cracked welds or loosened
parts.
Perform all daily lubrication and service.
If the operations were in salt water or other corrosive materials,
make sure to flush the affected equipment with fresh water.
Operating in an extremely dusty or hot
Clean the air intake filters on a more frequent basis.
environment.
Clean the radiator and oil cooler fins to remove embedded dirt
and dust.
Clean the fuel system intake strainer and fuel filter more
frequently.
Inspect and clean as required the starter and alternator.
Operating in rocky terrain.
Check the undercarriage and track assemblies for damage or
excessive wear.
Inspect for loose or damaged fittings or bolts.
Relax track tension.
On a more frequent basis, inspect the front end attachments for
damage or excessive wear.
Install a top guard and front guard as required for protection
against falling rock.
Operating in extreme cold.
Use the proper fuel for the temperature conditions.
Using a hydrometer, check the antifreeze to make sure that it is
providing the proper cold weather freeze protection.
Verify the condition of the batteries. In extremely cold weather
remove the batteries at night and store them in a warmer area.
Remove mud buildup as soon as possible to prevent it from
freezing to the undercarriage and causing damage.
Inspection, Maintenance and Adjustment
OP001141
4-89
Inspection, Maintenance and Adjustment
OP001141
4-90
OP001174
5Transportation
Obey all local, state or federal regulations for the transportation
of the excavator. If unsure of regulations check with local
authorities.
Check the intended route for road width, overhead clearances,
weight restrictions, and traffic control regulations. Special
approval or permits may be required.
LOADING AND UNLOADING
Warning for Counterweight and Front
Attachment Removal
DANGER
DOOSAN warns any user, that removal of the counterweight
from the machine, front attachment or any other part, may
affect the stability of the machine. This could cause
unexpected movement, resulting in death or serious
injuries. DOOSAN is not liable for any misuse.
Never remove counterweight or front attachment unless the
upper structure is in-line with the lower structure.
FG000371
Never rotate the upper structure once the counterweight or
Figure 1
front attachment has been removed.
Transportation
OP001174
5-1
WARNING
When transporting the machine, know the width, height,
length and weight.
Loading or unloading the machine can be a dangerous
operation. Make sure to run the engine at the lowest speed
setting, and travel at the slowest speed possible.
Make sure that ramp being used can handle the weight of
the machine. If required, add blocking under the ramp for
additional support.
Make sure that ramp surface is free of grease or mud that
could cause the machine to slip or slide.
Make sure that trailer is parked on firm, level ground before
attempting to load/unload the excavator.
If it is required to turn the machine while it is on the trailer,
make sure to do this at the slowest engine and travel
speeds possible.
Make sure to secure the excavator onto the trailer as
required by local transportation laws.
Total Height
Total Width
Total Length
Weight
Remarks
6.25 m Boom
3,345 mm
3,200 mm
10,620 mm
29.3 metric tons
3.1 m Arm
(11' 0")
(10' 6")
(418.11 in)
(32.23 tons)
600 G Shoe
1.
Make sure that trailer is parked on firm, level ground. See
Figure 2.
2.
Make sure that ramps that are being used are designed to
handle the weight of the excavator. If required, add
90 ~ 110
blocking under the ramp to provide additional support.
3.
The ramp angle should be less than or not exceeding a 15°
angle. Ramps steeper than this may cause a problem
when loading or unloading.
15
FG000325
Figure 2
Transportation
OP001174
5-2
4.
Set the travel speed selector switch to "O" (OFF) position.
See Figure 3.
O
I
II
FG016016
Figure 3
5.
Turn "OFF" auto idle selector button (1, Figure 4). The
1
indicator symbol will be disappeared.
6.
Set engine speed to "LOW IDLE."
1
2
6
7
FG013833
Figure 4
7.
If the machine is equipped with work equipment, set the
work equipment at the front, and travel forward to load it.
90 ~ 110
15
FG000325
Figure 5
8.
The unit does not require disassembly for normal
over-the-road transportation. If the boom and arm need to
be removed, the counterweight will place more weight on
the rear of the machine. Make sure to back the excavator
onto the trailer so the counterweight end of the excavator is
positioned on the ramp first. See Figure 6.
15
FG000326
Figure 6
Transportation
OP001174
5-3
9.
Extend bucket and arm cylinders to maximum length and
then lower the boom slowly.
FG000327
Figure 7
10. Set safety lever on "LOCK" position.
Unlock
Lock
FG015867
Figure 8
11. Shut down engine by turning key to "O" (OFF) position
(Figure 9).
O
I
12. Remove key from starter switch.
FG000175
Figure 9
13. Make sure to secure the excavator onto the trailer before
transporting. Place blocking (1, Figure 10) in front of and
behind each track. Tie front and rear (2, Figure 12) and tie
down point (3, Figure 12) on the lower frame with wire
cable as required by local transportation laws.
1
14. Refer to the Dimensions for Transportation table and
1
drawing for overall machine height and width
measurements. Make sure to position the excavator as
shown. If not transported in this position, the height
2
measurements may be different.
FG000334
Figure 10
Transportation
OP001174
5-4
2
2
2
3
2
3
3
3
FG014870
Figure 11
LIFTING WITH SLING
WARNING
Improper lifting can allow load to shift and cause injury or
damage.
1.
Refer to “Specification” on page 7-1 of this manual for
information on weight and dimensions.
2.
Use properly rated cables and slings for lifting.
3.
Position machine for a level lift.
4.
Lifting cables should have a long enough length to prevent
contact with the machine. Spreader bars may be required.
NOTE: If spreader bars are used, be sure that cables
FG016361
are properly secured to them and that angle of
Figure 12
the cables is factored into the lift strength.
Transportation
OP001174
5-5
Transportation
OP001174
5-6
OP000769
6Troubleshooting
Anytime that a malfunction occurs, take immediate corrective
action. Check for and investigate the cause of the malfunction. A
schedule maintenance program can prevent malfunctions from
occurring by doing preventative maintenance. A systematic
approach should be taken to troubleshooting, since several
overlapping malfunctions may give the appearance of a problem
that does not exist. If cause for the malfunction cannot be
determined, contact your DOOSAN distributor. Never perform
an adjustment of or disassembly of, hydraulic components,
electrical and electronic components, without first consulting a
DOOSAN distributor.
ELECTRICAL SYSTEM
Problem
Cause
Remedy
Battery will not hold a
Low battery power.
Clean and retighten.
charge.
Alternator belt loose or bad.
Tighten or replace belt.
Loose or corroded terminals.
Tighten or replace as required.
Alternator faulty.
Repair or replace as required.
Low battery power.
Internal battery short.
Replace battery.
Short circuit in wiring.
Repair as required.
Engine speed is not
Speed control dial failed.
Replace control dial.
controllable.
Throttle controller failed.
Replace controller.
Speed control motor failed.
Repair or replace as required.
Blown fuse.
Replace fuse.
Wiring harness damaged.
Repair or replace as required.
Connector failed.
Repair or replace as required.
Work mode (Power mode or
Blown fuse.
Replace fuse.
Economy mode) selector
Work mode selector switch failed.
Replace switch.
does not work.
Connector failed.
Replace connector.
Wiring harness damaged.
Repair or replace as required.
e-EPOS controller failed.
Repair or replace as required.
Troubleshooting
OP000769
6-1
Problem
Cause
Remedy
Working mode selector does
Blown fuse.
Replace fuse.
not work.
Working mode selector switch.
Replace switch failed.
Connector failed.
Replace connector.
Wiring harness damaged.
Repair or replace as required.
e-EPOS controller failed.
Repair or replace as required.
ENGINE
Problem
Cause
Remedy
Starter does not operate.
Low battery power.
Charge battery.
Poor terminal contact.
Clean and tighten connections.
Starter switch failed.
Replace switch.
Starter relay failed.
Replace relay.
Starter controller failed.
Replace controller.
Wiring harness faulty.
Replace harness.
Battery relay failed.
Replace relay.
Blown fuse.
Replace fuse.
Starter engages, engine
Fuel gelled in cold weather.
Replace fuel.
does not start.
Fuel filters plugged.
Replace filters.
Water or dirt in fuel system.
Clean system and add new fuel.
Air in fuel system.
Purge air from system.
Engine stop control failed.
Contact your DOOSAN dealer.
Engine stop relay failed.
Replace relay.
Blown fuse.
Replace fuse.
Engine starts, runs only at
Engine oil viscosity incorrect.
Change oil.
low speed or shuts down.
Clogged or dirty fuel injectors.
Clean injectors.
Fuel filters plugged.
Replace filters.
Troubleshooting
OP000769
6-2
Problem
Cause
Remedy
Engine knocks, runs
Low engine oil.
Refill.
unevenly or surges.
Plugged air intake system.
Clean system and replace filter.
Injection pump out of adjustment.
Contact your DOOSAN dealer.
Plugged fuel filter.
Replace fuel filter.
Water or dirt in fuel system.
Clean system and add new fuel.
Clogged or dirty fuel injectors.
Clean injectors.
Engine has poor power.
Plugged air intake system.
Clean system and replace filter.
Clogged or dirty fuel injectors.
Clean injectors.
Fuel filters plugged.
Replace filters.
Engine speed control cable out of
Readjust.
adjustment.
Injection pump out of adjustment.
Contact your DOOSAN dealer.
Valve backlash faulty.
Adjust backlash.
Engine runs hot.
Low coolant level.
Add coolant.
Thermostat faulty.
Replace thermostat.
Radiator cap faulty.
Replace radiator cap.
Radiator core plugged.
Clean radiator.
Oil cooler core plugged.
Clean oil cooler.
Fan belt loose or damaged.
Tighten or replace as required.
Temperature sensor faulty.
Replace sensor.
HYDRAULIC SYSTEM
Problem
Cause
Remedy
None of the controls
Hydraulic pump failed.
Contact your DOOSAN dealer.
function (loud noise from
Low hydraulic oil level.
Add hydraulic oil as required.
pumps).
Suction line plugged or damaged.
Clean or replace as required.
None of the controls
Pilot pump failure.
Contact your DOOSAN dealer.
function (no noise from
Cut off solenoid valve failed.
Replace solenoid.
pumps).
Pilot cutoff switch is ON.
Adjust pilot cutoff switch clearance.
Troubleshooting
OP000769
6-3
Problem
Cause
Remedy
All actuators have low
Low hydraulic oil level.
Add hydraulic oil as required.
power.
Suction filter clogged.
Clean filter.
Hydraulic pumps faulty.
Contact your DOOSAN dealer.
Main relief pressure too low.
Contact your DOOSAN dealer.
Hydraulic pumps excavating.
Bleed air from hydraulic pumps.
Only one or two actions
Overload relief pressure too low.
Reset pressure.
have little or no power.
Makeup check valve leaking.
Clean or replace as required.
Control valve spool faulty.
Replace valve spool.
Dirt in valve spool.
Clean or replace as required.
Actuator failed.
Repair or replace as required.
Cylinder seal failed.
Repair or replace as required.
Cylinder rod damaged.
Repair or replace as required.
Remote control valve failed.
Replace control valve.
Wrong pilot line connection.
Reconnect pilot lines.
Oil temperature too high.
Oil cooler faulty.
Contact your DOOSAN dealer.
Fan belt loose.
Tighten fan belting as required.
SWING SYSTEM
Problem
Cause
Remedy
No swinging motion.
Swing brake valve faulty.
Replace brake valve.
Hydraulic timer faulty.
Replace timer.
Low brake release pressure.
Adjust pressures.
Swing motor failed.
Replace swing motor.
Remote control valve failed.
Replace control valve.
Wrong pilot line connection.
Reconnect pilot lines.
Swing motion jerky.
Swing gear worn.
Replace swing gear.
Swing bearing damaged.
Replace bearing.
Improper lubrication.
Add grease.
Troubleshooting
OP000769
6-4
TRAVEL SYSTEM
Problem
Cause
Remedy
Travel motion does not
Center joint leaking.
Repair or replace as required.
function.
Parking brake will not release.
Repair parking brake.
Travel motor failed.
Repair or replace as required.
Remote control valve failed.
Repair or replace as required.
Wrong pilot line connection.
Reconnect pilot lines.
Travel speed is too low.
Track tension too high or too low.
Adjust tension.
Damaged rollers or idlers.
Repair or replace as required.
Track frame damaged.
Repair as required.
Parking brake will not release.
Repair parking brake.
Troubleshooting
OP000769
6-5
Troubleshooting
OP000769
6-6
OP001175
7Specification
STANDARD SPECIFICATION
SPECIFICATION
COMPONENT
METRIC
ENGLISH
Bucket
CECE
1.1 m3
1.44 yd3
capacity
PCSA
1.27 m3
1.66 yd3
Equipment weight
29.4 metric tons
32.3 tons
Engine
Model
DL08
Type
Water cooled - 6 cylinders
Rated output
200 ps @1,900 rpm
197 hp @1,900 rpm
Maximum torque
93 kg•m @ 1,300 rpm
673 ft lb @ 1,300 rpm
Fuel tank capacity
500 liters
132 U.S. gal.
Hydraulic
Type
Axial piston
pump
Discharging pressure
350 kg/cm2
5,000 psi
Maximum discharge quantity
2 x 247 liters/min
2 x 65.2 U.S. gpm
Hydraulic oil
Tank Level
160 liters
42 U.S. gal.
capacity
System
280 liters
74 U.S. gal.
Performance
Digging
Bucket
18.0 metric tons
19.8 tons
capability
Arm
13.4 metric tons
14.8 tons
Swing speed
9.9 rpm
Travel speed
High speed
5.1 km/h
3.17 MPH
Low speed
3.0 km/h
1.86 MPH
Traction force
High speed
13.7 metric tons
15.1 tons
Low speed
25.2 metric tons
27.7 tons
Gradeability
35° (70% slope)
Ground pressure
0.56 kg/cm2
7.97 psi
Ground clearance
500 mm
19.7 in
Track shoe width
600 mm
23.6 in
Upper roller qty.
2 per side
Bottom roller qty.
9 per side
Specification
OP001175
7-1
OVERALL DIMENSIONS
One - Piece Boom
H
A
I
J
B
C
O
G
F
N
M
K
D
L
E
FG000316
Figure 1
6.245 m (20' 6") BOOM
10.0 m (32' 10") BOOM
DIMENSION
3.1 m (10' 2") ARM
2.5 m (8' 2") ARM
3.75 m (12' 4") ARM
7.0 m (22' 12") ARM
A
10,620 mm (34' 10")
10,740 mm (35' 3")
10,660 mm (35' 0")
14,365 mm (47' 1")
B
3,200 mm (10' 6")
C
7,420 mm (24' 4")
7,540 mm (24' 9")
7,460 mm (24' 6")
11,165 mm (36' 7")
D
4,010 mm (13' 2")
E
4,930 mm (16' 2")
F
1,175 mm (3' 10")
G
3,345 mm (10' 12")
3,475 mm (11' 5")
3,475 mm (11' 5")
3,350 mm (10' 12")
H
2,960 mm (9' 9")
I
1,500 mm (4' 11")
J
1,460 mm (4' 9")
K
2,600 mm (8' 6")
L
3,200 mm (10' 6")
M
600 mm (23.62 in)
N
500 mm (19.69 in)
O
3,065 mm (10' 1")
Specification
OP001175
7-2
Two - Piece Boom
H
A
I
J
B
C
O
G
F
N
M
K
D
L
E
FG015138
Figure 1
6.255 m (20' 6") Two-piece BOOM
DIMENSION
3.1 m (10' 2") ARM
2.5 m (8' 2") ARM
3.75 m (12' 4") ARM
A
10,680 mm (35' 0")
10,760 mm (35' 4")
10,660 mm (35' 0")
B
3,200 mm (10' 6")
C
7,480 mm (24' 6")
7,560 mm (24' 10")
7,460 mm (24' 6")
D
4,010 mm (13' 2")
E
4,930 mm (16' 2")
F
1,175 mm (3' 10")
G
3,450 mm (11' 4")
3,430 mm (11' 3")
3,620 mm (11' 10")
H
2,960 mm (9' 9")
I
1,500 mm (4' 11")
J
1,460 mm (4' 9")
K
2,600 mm (8' 6")
L
3,200 mm (10' 6")
M
600 mm (23.62 in)
N
500 mm (19.69 in)
O
3,065 mm (10' 1")
Specification
OP001175
7-3
WORKING RANGE
One - Piece Boom
E
11
10
9
8
7
6
5
C
4
D
3
2
1
G.L
0
0
1
2
3
4
5
6
7
8
9
10
11
-1
-2
-3
-4
B
-5
-6
-7
-8
A
Figure 2
FG000318
BOOM
6.245 m (20' 6")
10.0 m (32' 10")
DIM.
ARM
3.1 m (10' 2")
2.5 m (8' 2")
3.75 m (12' 4")
7.0 m (22' 12")
Max. Digging
A
10,745 mm (35' 3")
10,165 mm (33' 4")
11,270 mm (36' 12")
17,520 mm (57' 6")
Reach
Max. Digging
B
7,360 mm (24' 2")
6,760 mm (22' 2")
8,010 mm (26' 3")
13,855 mm (45' 5")
Depth
Max. Digging
C
10,330 mm (33' 11")
9,970 mm (32' 8")
10,410 mm (34' 2")
14,175 mm (46' 6")
Height
Max. Loading
D
7,260 mm (23' 10")
6,930 mm (22' 9")
7,365 mm (24' 2")
11,950 mm (39' 2")
Height
Min. Swing
E
4,055 mm (13' 4")
4,060 mm (13' 4")
4,060 mm (13' 4")
6,125 mm (20' 1")
Radius
Specification
OP001175
7-4
Two - Piece Boom
E
11
10
9
8
7
6
5
C
4
D
3
2
1
G.L
0
0
1
2
3
4
5
6
7
8
9
10
11
-1
-2
-3
-4
B
-5
-6
-7
-8
A
FG015139
Figure 3
BOOM
6.255 m (20' 6") Two-piece
DIM.
ARM
3.1 m (10' 2")
2.5 m (8' 2")
3.75 m (12' 4")
A
Max. Digging Reach
10,870 mm (35' 8")
10,280 mm (33' 9")
11,425 mm (37' 6")
B
Max. Digging Depth
7,055 mm (23' 2")
6,450 mm (21' 2")
7,660 mm (25' 1")
C
Max. Digging Height
12,085 mm (39' 8")
11,580 mm (37' 12")
12,435 mm (40' 9")
D
Max. Loading Height
8,860 mm (29' 1")
8,355 mm (27' 5")
9,210 mm (30' 3")
E
Min. Swing Radius
2,895 mm (9' 6")
3,030 mm (9' 11")
2,970 mm (9' 9")
Specification
OP001175
7-5
APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or ground water; settling
or compaction due to overhead weight and chemical or
industrial processing or
changes due to thermal or
chemical transformations
could
all
increase value of
weights listed in table.
LOW WEIGHT OR
MEDIUM WEIGHT OR
HIGH WEIGHT OR
DENSITY
DENSITY
DENSITY
MATERIAL
1,100 KG/M3
1,600 KG/M3
2,000 KG/M3
(1,850 LB/YD3), OR
(2,700 LB/YD3), OR
(3,370 LB/YD3), OR
LESS
LESS
LESS
3
401 kg/m
Charcoal
---------------------
---------------------
(695 lb/yd3)
3
433 kg/m
Coke, blast furnace size
---------------------
---------------------
(729 lb/yd3)
3
449 kg/m
Coke, foundry size
---------------------
---------------------
(756 lb/yd3)
3
801 kg/m
Coal, bituminous slack, piled
---------------------
---------------------
(1,350 lb/yd3)
3
881 kg/m
Coal, bituminous r. of m., piled
---------------------
---------------------
(1,485 lb/yd3)
3
897 kg/m
Coal, anthracite
---------------------
---------------------
(1,512 lb/yd3)
3
1,009 kg/m
Clay, DRY, in broken lumps
---------------------
---------------------
(1,701 lb/yd3)
3
1,746 kg/m
Clay, DAMP, natural bed
---------------------
---------------------
(2,943 lb/yd3)
3
1,506 kg/m
Cement, Portland, DRY granular
---------------------
---------------------
(2,583 lb/yd3)
3
1,362 kg/m
Cement, Portland, DRY clinkers
---------------------
---------------------
(2,295 lb/yd3)
3
1,522 kg/m
Dolomite, crushed
---------------------
---------------------
(2,565 lb/yd3)
3
1,202 kg/m
Earth, loamy, DRY, loose
---------------------
---------------------
(2,025 lb/yd3)
3
1,522 kg/m
Earth, DRY, packed
---------------------
---------------------
(2,565 lb/yd3)
3
1,762 kg/m
Earth, WET, muddy
---------------------
---------------------
(2,970 lb/yd3)
Specification
OP001175
7-6
LOW WEIGHT OR
MEDIUM WEIGHT OR
HIGH WEIGHT OR
DENSITY
DENSITY
DENSITY
MATERIAL
1,100 KG/M3
1,600 KG/M3
2,000 KG/M3
(1,850 LB/YD3), OR
(2,700 LB/YD3), OR
(3,370 LB/YD3), OR
LESS
LESS
LESS
3
961 kg/m
Gypsum, calcined, (heated, powder)
---------------------
---------------------
(1,620 lb/yd3)
3
1,522 kg/m
Gypsum, crushed to 3 inch size
---------------------
---------------------
(2,565 lb/yd3)
3
1,810 kg/m
Gravel, DRY, packed fragments
---------------------
---------------------
(3,051 lb/yd3)
3
1,922 kg/m
Gravel, WET, packed fragments
---------------------
---------------------
(3,240 lb/yd3)
3
1,282 kg/m
Limestone, graded above 2
---------------------
---------------------
(2,160 lb/yd3)
Limestone, graded
1,362 kg/m3
---------------------
---------------------
1-1/2 or 2
(2,295 lb/yd3)
3
1,522 kg/m
Limestone, crushed
---------------------
---------------------
(2,565 lb/yd3)
3
1,602 kg/m
Limestone, fine
---------------------
---------------------
(2,705 lb/yd3)
3
1,282 kg/m
Phosphate, rock
---------------------
---------------------
(2,160 lb/yd3)
3
929 kg/m
Salt
---------------------
---------------------
(1,566 lb/yd3)
3
529 kg/m
Snow, light density
---------------------
---------------------
(891 lb/yd3)
3
1,522 kg/m
Sand, DRY, loose
---------------------
---------------------
(2,565 lb/yd3)
3
1,922 kg/m
Sand, WET, packed
---------------------
---------------------
(3,240 lb/yd3)
3
1,362 kg/m
Shale, broken
---------------------
---------------------
(2,295 lb/yd3)
3
529 kg/m
Sulphur, broken
---------------------
---------------------
(1,620 lb/yd3)
Specification
OP001175
7-7
Specification
OP001175
7-8
1INDEX
Numerics
Shimming Procedures for Installed Bucket 4-72
1,000 Hour / 6 Month Service 4-43
Teeth and Side Cutters 4-21
10 Hour / Daily Service 4-14
Tooth 4-69
12,000 Hour / 6 Year Service 4-59
2,000 Hour / Yearly Service 4-51
C
250 Hour / Monthly Service 4-27
Cabin Light 2-56
2-Pump Flow Control Switch 2-16
Cabin Storage Compartments 2-66
4,000 Hour / Biennial Service 4-58
Cabin Work Light Switch 2-11
50 Hour / Weekly Service 4-24
Ceiling Cover 2-62
500 Hour / 3 Month Service 4-34
Charge Warning Light 2-24
Check and Confirmation After Stopping Engine 3-
A
14
Abnormal State Warning Symbols 2-29
Cigarette Lighter 2-9
Adjust Valve Clearance 4-57
Circuit Breaker 2-56
Air Intake System 4-22
Clock 2-23, 2-38
Outer Element of Air Cleaner 4-39
Cold Weather Hydraulic System Warm-up 3-11
Replace Outer Air Cleaner Element 4-52
Cold Weather Starting 3-6
Alternator and Starter 4-57
Communication
Antifreeze Concentration Tables 4-79
Error Warning 2-28
Antivibration Shock Mounts 4-57
Indicator 2-27
Arm and Bucket Joint Pins 4-24
Component Locations 2-2
Ashtray 2-66
Constant Speed Button 2-12
Audio Control Panel 2-11
Coolant Temperature Warning Light 2-25
Auto Idle Mode 3-21
Cooling System
Auto Idle Selection 2-47
Clean Radiator, Oil Cooler and Air Conditioner
Auto Idle Selector Button 2-34
Condenser Coil 4-38
Auxiliary Mode Switch 2-19
Engine 4-77
Engine Coolant Temperature Warning Light 2-
25
B
Oil Cooler Dust Net 4-20
Batteries 4-33
Radiator Coolant 4-53
Battery 4-73
Refill Cooling System 4-20
Box Door 2-69
Cracks and Faulty Welds 4-22
Electrolyte Level 4-74
Cup Holder 2-68
Terminals 4-74
Cycle Time Tests 4-57
Voltage 2-28
Bolt and Nut Inspection 4-61
D
Boom and Arm Joint Pins 4-27
Boost Mode 3-22
Description of Lubrication and Service Chart 4-10
Booster Cable 3-8
Digital Clock 2-23
Breaker / Booster Button (Rignt-hand Work Lever)
Display Selection 2-37
2-17
Display Selector Button 2-36
Breaker Selection 2-47
Door Side Latch 2-65
Bucket 4-69
Down Arrow Button 2-36
Installation 4-71
O-ring 4-70
E
Shimming Procedures 4-71
Economy Mode 3-21
Index
950106-00284E
8-1
Economy Mode Selection 2-46
Engine Coolant Temperature Gauge 2-22
Economy Mode Selector Button 2-33
Fuel Gauge 2-22
Electrical System 4-73, 6-1
Hour Meter 2-24
Engine 6-2
Hydraulic Oil Temperature 2-23
Adjust Valve Clearance 4-57
Multifunction Gauge 2-23, 2-27
Check and Adjust Engine 4-48
General Venting 4-86
Check Warning Light 2-25
Coolant Temperature Gauge 2-22
H
Coolant Temperature Warning Light 2-25
Handling a New Excavator 3-1
Cover 2-69
Handling of Accumulator 4-82
Emergency Stop Switch 2-9
Hanger 2-68
Fan Belt 4-29, 4-30
Head Bolt Torques 4-57
Head Bolt Torques 4-57
Headlight Switch 2-10
Oil and Filter 4-26, 4-35
Heater and Air Conditioner 2-49
Oil Level 4-14
Additional Operating Instruction 2-54
Oil Pressure Warning Light 2-24
Control Panel 2-8, 2-50
Shutdown 3-13
Filter 4-36, 4-47
Speed 2-28
Location of Controls and Vents 2-49
Speed Control Dial 2-9
Memory Function of Used Mode 2-54
Start 3-4
Refrigerant 4-48
Start and Stop 3-2
System 4-60
ESC Button 2-37
Horn Button 2-16
Excavator Rated Lift Capacity Tables 1-51
Hose Clamps 4-33
Hour Meter 2-24
F
Hydraulic System 6-3
Fan Belt 4-26
Flow Control 2-44
Filter / Oil Info 2-39
Front Hydraulic Pump Pressure 2-29
Filter State 2-29
General Venting 4-86
Flow Control 2-44
Hydraulic Breaker 3-33
Flow Control Button 2-34
Hydraulic Hoses and Tubing 3-33
Front
Oil and Filter 3-37
Bottom Window 2-64
Operation 3-34
End Attachments 4-33
Selection 3-33
Hydraulic Pump Pressure 2-29
Hydraulic Cylinders 4-85
Upper Windows 2-63
Hydraulic Oil Exchange 4-55
Windows 2-63
Hydraulic Oil Return Filter 4-33, 4-44
Fuel
Hydraulic Oil Tank 4-15
Change Fuel Cap Filter 4-49
Hydraulic Oil Temperature Gauge 2-23
Filter 4-42
Leaks in the Hydraulic System 4-16
Gauge 2-22
Main System Pump 4-85
Heater Switch 2-14
Oil Exchange 4-55
Level 4-17
Rear Hydraulic Pump Pressure 2-29
System 4-42
Swing Motor 4-86
Transfer Pump 4-80
Warm-up 3-10
Tank Drain Valve 4-26
Transfer Pump 4-80
I
Fuse
Indicator
Boxes 2-57, 4-75
Communication Indicator 2-27
Fuses 4-75
Indicator Lights
Fusible Link 2-57
Charge Warning Light 2-24
Identification 4-76
Coolant Temperature Warning Light 2-25
Engine Check Warning 2-25
G
Engine Oil Pressure Warning Light 2-24
Gauges
Preheating Indicator Light 2-26
Index
950106-00284E
8-2
Work Light 2-26
Rainy or Humid Conditions 3-45
Inspecting Engine Before Starting 3-2
Salt Water Areas 3-45
Inspection, Maintenance and Adjustment 4-1
Operation of All Switches 4-22
Instrument Panel 2-18, 2-20
Operation Selection Display 2-46
Intermittent Speed Button 2-13
Operation Under Unusual Conditions 3-43
Operational Checks Before Starting Engine 3-3
Operational Controls and Panels 2-6
L
Operator's Area 2-4
Language 2-38
Operator's Compartment Light 2-56
Leaks in the Fuel System 4-17
Outer Air Cleaner Element 4-52
Leaks in the Hydraulic System 4-16
Outer Element of Air Cleaner 4-39
Levers
Overall Dimensions 7-2
Adjusting Reclining 2-59
Overload Warning Switch (Optional) 2-15
Adjusting the Seat Forward 2-58
Adjusting the Seat's Angle 2-58
Safety Lever 2-18
P
Lifting 3-41
Panels
Lifting With Sling 5-5
Air Conditioner Control Panel 2-8
Lights
Audio Control 2-11
Cabin 2-56
Heater and Air Conditioner 2-49
Loading and Unloading 5-1
Heater and Air Conditioner Control Panel 2-50
Locations of Safety Labels 1-4
Instrument 2-18
Long Term Storage 4-87
Instrument Panel 2-20
Lower Wiper Switch (Optional) 2-13
Wiper Control 2-12
Lubrication and filters 3-2
Parking Excavator 3-31
Lubrication and Service Chart 4-8
Password
Activated 2-21
Set Password 2-42
M
Password Activated 2-21
Magnetic Clutch 4-60
Photo Sensor 2-18
Main Menu 2-35
Pilot Cutoff Switch 2-56
Maintenance in Special Conditions 4-89
Pilot Filter 4-33, 4-45
Maintenance Intervals 4-12
Pins and Bushings 4-33
Miscellaneous Access Doors 2-69
Power Boost Selection 2-47
Mode Selection 3-20
Power Mode 3-20
Mode Selector Buttons 2-33
Power Mode Selection 2-46
Multifunction Gauge 2-23, 2-27
Power Mode Selector Button 2-33
Power Socket 2-9, 2-16
N
Preheating Light 2-26
Nuts and Bolts 4-33
Preliminary Work Machine Setup for Maintenance
4-4
O
Preventive Maintenance 4-1
Oil Cooler Dust Net 4-20
Pump Pressure
Oil Level of Travel Reducer 4-31
Front Pump 2-29
Opening the Window 2-63, 2-64
Rear Pump 2-29
Operating
Controls 2-1
Q
Instructions 3-20
Quick Clamp Operation Selection 2-48
Precautions 3-26
Quick Clamp Switch (Optional) 2-14
Techniques 3-41
Operation 3-1
R
Operation In
Radiator Coolant 4-53
Extreme Cold 3-43
Rear Hydraulic Pump Pressure 2-29
Extreme Heat 3-44
Refill Cooling System 4-20
High Altitudes 3-46
Reverse Fan Switch 2-15
Index
950106-00284E
8-3
Rotating Button 2-17
Structural Damage 4-57
Suction Strainer 4-55
Sun Visor 2-67
S
Swing
Safety 1-1
Bearing 4-25
Safety Lever 2-18, 3-14
Gear and Pinion 4-34
Safety Precautions 4-3
Motor 4-86
Seat 2-58
Reduction Device 4-19, 4-32, 4-43, 4-51
Seat Adjustment
System 6-4
Adjusting height of Seat and Depth of Cushion
Switches
2-58
2-Pump Flow Control 2-16
Adjusting Height/Angle of Armrest 2-61
Auto Idle Selector Button 2-34
Adjusting Reclining 2-59
Automatic Travel Speed Control 3-15
Adjusting the Seat Forward 2-58
Auxiliary Mode 2-19
Adjustment of Lumbar Support 2-59
Booster Button 2-17
Headrest 2-59
Cabin Work Light Switch 2-11
Left and Right Control Stand Height Adjustment
Cigar Lighter 2-9
2-61
Constant Speed Button 2-12
Left and Right Control Stand Location 2-60
Display Selector Button 2-36
Seat Belt 2-59, 4-22
Down Arrow Button 2-36
Selection Button 2-36
Economy Mode Selector Button 2-33
Selection of
Engine Emergency Stop 2-9
Breaker 2-46, 2-47
Engine Speed Control 3-20
Overload Alarm 2-47
Engine Speed Control Dial 2-9
Power Boost Selection 2-46, 2-47
ESC Button 2-37
Quick Clamp Operation 2-48
Flow Control Button 2-34
Shear 2-46, 2-47
Fuel Heater (Optional) 2-14
Serial Numbers 4-2
Headlight Switch 2-10
Set Password 2-42
Home Button 2-36
Setting Clock 2-38
Horn Button 2-16
Shear Button 2-17
Intermittent Speed Button 2-13
Shear Selection 2-47
Lower Wiper (Optional) 2-13
Shimming Procedures for Installed Bucket 4-72
Overload Warning (Optional) 2-15
Shutdown
Pilot Cutoff Switch 2-56
Check and Confirmation After Stopping Engine
Power Mode Selector Button 2-33
3-14
Power Socket 2-9, 2-16
Engine Shutdown 3-13
Quick Clamp (Optional) 2-14
Parking Excavator 3-31
Reverse Fan 2-15
Side Door 2-69
Rotating Buttons 2-17
Specification 7-1
Selection Button 2-36
Standard Mode Selection 2-46
Shear Buttons 2-17
Standard Specification 7-1
Starter Switch 2-8
Starter Switch 2-8
Travel Speed Selector Switch 2-10
Starting Engine Using a Booster Battery 3-8
Travel/Swing Alarm (Optional) 2-14
Start-up
Up Arrow Button 2-35
Cold Weather Hydraulic System Warm-up 3-11
Warning Light (Optional) 2-13
Cold Weather Starting 3-6
Washer Button 2-13
Engine Start 3-4
Symbols
Hydraulic System Warm-up 3-10
Air Cleaner Clogged Warning 2-31
Inspection Before Starting Engine 3-2
Hydraulic Oil Overheat Warning 2-30
Operational Checks Before Starting Engine 3-3
Overload Warning (Optional) 2-32
Starting Engine Using a Booster Battery 3-8
Pilot Filter Clogged Warning 2-30
Stereo 2-55
Return Filter Clogged Warning 2-31
Audio Control Panel 2-11
Index
950106-00284E
8-4
T
Hydraulic Cylinders 4-85
Table of Recommended Lubricants 4-6
Main System Pump 4-85
Towing Procedure 3-32
Swing Motor 4-86
Track Assemblies 4-26
Visibility Information 1-15
Track Tension 4-83
Transportation 5-1
W
Travel 3-15
Warning Light Switch 2-13
Control Lever Operation 3-16
Washer Button 2-13
Instructions 3-17
Water Separator 4-18
Reduction Device 4-31, 4-32, 4-46
Weight of Workload Materials 7-6
Speed Selector Switch 2-10
Window Washer Liquid 4-21
System 6-5
Windows
Travel/Swing Alarm Switch (Optional) 2-14
Front 2-63
Troubleshooting 6-1
Front Bottom 2-64
Front Upper 2-63
U
Opening 2-63, 2-64
Unloading and Loading 5-1
Sun Visor 2-67
Up Arrow Button 2-35
Wiper Control Panel 2-12
Work Levers (Joysticks) (ISO Style) 3-23
Work Light Indicator Light 2-26
V
Working Range 7-4
Venting and Priming Hydraulic System 4-85
General Venting 4-86
Index
950106-00284E
8-5