Doosan DX140LC Operation And Maintenance Manual Download | Manualshive

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OP000599

4-61

Inspection, Maintenance and Adjustment

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.

NO.

POINT TO BE INSPECTED

BOLT

DIA. MM

QTY.

BOLT

HEAD

SIZE

TORQUE

kg•m

Nm

ft lb

1

Joint bolt with engine
mounting bracket and
engine

pump side

16

8

24

27

264

195

fan side

10

8

17

6.5

64

47

2

Joint bolt and nut
between engine mount-
ing bracket and frame

pump side

20

2

30

46

451

333

fan side

20

2

30

46

451

333

3

Radiator mounting bolt

16

4

24

27

264

195

4

Tightening bolt for hydraulic oil tank

16

4

24

27

264

195

5

Tightening bolt for fuel tank

16

4

24

27

264

195

6

Tightening bolt for pump

10

12

17

6.5

64

47

7

Tightening bolt for control valve

16

4

24

27

264

195

8

Tightening bolt for swing reduction device

16

9

24

27

264

195

9

Tightening bolt for swing motor

12

10

10 (S)

11

108

80

10

Tightening bolt for battery

10

2

17

6.5

64

47

11

Joint bolt with cabin mounting rubber and
frame

10

16

17

6.5

64

47

Joint bolt with cabin mounting rubber and
cabin

16

4

24

21

205

152

12

Joint bolt with swing bearing and upper
frame

20

36

30

55

539

398

Joint bolt with swing bearing and bottom
frame

20

36

30

55

539

398

13

Tightening bolt for travel device

16

40

24

30

294

217

Tightening bolt for sprocket

16

30

24

30

294

217

14

Tightening bolt for upper roller

20

2

30

55

539

398

15

Tightening bolt for bottom roller

16

56

24

27

264

195

16

Tightening bolt for track guard

16

8

24

27

264

195

17

Bolt for track shoes

16

368

24

39

382

282

18

Tightening bolt for front pin

16

10

24

27

264

195

19

Breaker Filter (Optional)

1

30

27

264

195

20

Grease valve for track adjuster

PF 1/2

2

27

14

137

101

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Summary of Contents for DX140LC

Page 1: ...mended that consumers periodically contact their distributors for recent documentation on purchased equipment This documentation may include attachments and optional equipment that is not available in your machine s package Please call your distributor for additional items that you may require Illustrations used throughout this manual are used only as a representation of the actual piece of equipm...

Page 2: ......

Page 3: ... Maintenance 1 35 Battery 1 44 Towing 1 46 Shipping and Transportation 1 47 Excavator Rated Lift Capacity Tables 1 48 Operating Controls 2 1 Component Locations 2 4 Operator s Area 2 6 Operational Controls and Panels 2 8 Instrument Panel 2 24 Multifunction Gauge and Graphic Information 2 31 Mode Selector Buttons 2 36 Setting Main Menu 2 38 Flow Control 2 47 Operation Selection Display 2 49 Heater ...

Page 4: ...1 Starting and Stopping the Engine 3 2 Safety Lever 3 13 Travel 3 14 Operating Instructions 3 20 Operating Precautions 3 27 Parking Excavator 3 32 Towing Procedure 3 33 Hydraulic Breaker 3 34 Adjusting the Pump Flow 3 39 Operating Techniques 3 42 Operation Under Unusual Conditions 3 44 Inspection Maintenance and Adjustment 4 1 Preventive Maintenance 4 1 Preliminary Work Machine Setup for Maintenan...

Page 5: ...4 60 Bolt and Nut Inspection 4 61 Bucket 4 69 Electrical System 4 72 Engine Cooling System 4 76 Fuel Transfer Pump Optional 4 78 Handling of Accumulator 4 81 Track Tension 4 82 Venting and Priming Hydraulic System 4 84 Long Term Storage 4 86 Maintenance in Special Conditions 4 87 Transportation 5 1 Loading and Unloading 5 1 Lifting With Sling 5 5 Troubleshooting 6 1 Electrical System 6 1 Engine 6 ...

Page 6: ...K1030026E Table of Contents IV Overall Dimensions 7 2 Working Range 7 4 Approximate Weight of Workload Materials 7 6 Index 8 1 ...

Page 7: ...fications on page 1 15 4 General Hazard Information on page 1 15 5 Before Starting Engine on page 1 24 6 Machine Operation on page 1 28 7 Maintenance on page 1 35 8 Battery on page 1 44 9 Towing on page 1 46 10 Shipping and Transportation on page 1 47 11 Excavator Rated Lift Capacity Tables on page 1 48 DANGER Unsafe use of the excavator could lead to serious injury or death Operating procedures m...

Page 8: ...n in this manual apply only to intended uses of the machine If you use your machine for any unintended uses that are not specifically prohibited you must be sure that it is safe for any others In no event should you or others engage in prohibited uses or actions as described in this manual DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it...

Page 9: ...onal injury or accidents Always observe safety precautions and follow recommended procedures CAUTION This word is used on safety messages and safety labels and indicates potential of a hazardous situation that if not avoided could result in minor or moderate injury It may also be used to alert against a generally unsafe practice WARNING This word is used on safety messages and safety labels and in...

Page 10: ...fore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual are used you must be sure that you and others can do such procedures and actions safely and without damaging the machine If you are unsure about the safety of some procedures contact a DOOSAN distributor ...

Page 11: ... words Replace the illustrations if the illustrations are not visible When you clean the warning signs use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the safety signs Solvents gasoline or other harsh chemicals could loosen the adhesive that secures the warning sign Loose adhesive will allow the warning sign to fall off Replace any safety sign that is damag...

Page 12: ...s being jacked up with boom and arm Sound the horn to alert the people nearby before operating and make sure that all persons are clear of area Controls may be changed for attachments or operator preference Try control pattern before operating ARO1080L ARO1090L DANGER SERIOUS INJURY OR DEATH BY ELECTROCTION can occur if machine or attachments are not a safe distance from electrical power lines Lin...

Page 13: ...Opening a Front Window 2190 3388 190 00093 4 Warnings for a High pressure Cylinder 190 00122 FG000665 When raising window lock it in place with lock pins on both sides Falling window can cause injury 2190 3388 190 00093 190 00122 ARO1110L ...

Page 14: ... an accident which may involve injury to personnel It is very dangerous to make mistakes when performing such an adjustment or disassembly Be sure to read the procedures described in the Operation and Maintenance Manual carefully before adjusting the track tension 2190 3386A ARO1120L ARO1140L 190 00094 Sudden and unwanted machine movement can cause serious injury or death Always make sure when lea...

Page 15: ... caused by shortcircuiting batteries Surfuric acid in battery is poisonous It is strong enough burn skin eat holes in clothing and cause blindness if splashed eyes If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda or lime to help neutralize the acid 3 Flush your eyes with water for 10 15 minutes Get medical attention immediately 2190 2533A ARO1160L HOT OIL CAN CAUSE IN...

Page 16: ... 00097 HOT COOLANT CAN CAUSE INJURY OR BLINDNESS Never loosen or open radiator cap when coolant is hot and under pressure To open cap stop engine wait until radiator is cool Then loosen cap slowly to relieve the pressure 190 00692 EXPLOSIONHAZARD Keep away from flame Do not weld on or drill into the accumulator 190 00703 190 00099 ARO1180L ...

Page 17: ...hen Inspection and Maintenance 190 00695 190 00098 ARO1190L Rotating parts can cause personal injury Keep away from fan and belt when engine is run ning Stop engine before servicing 190 00694 190 00095 190 00557 190 00098 ARO1200L WARNING DO NOT OPERATE when performing inspection or maintenance 190 00695 ...

Page 18: ...OP000596 Safety 1 12 13 Warning for a Hot Surface 190 00648A 14 Caution for Hood 190 00522 190 00648 ARO1210L 190 00522 ARO1220L ...

Page 19: ...OP000596 1 13 Safety 15 Keep Out of the Swing Area 2190 3379A K1008571 16 Warnings for Front Attachments 190 00652 FG009521 2190 3379A K1008571 ARO1230L 190 00652 ...

Page 20: ...ANGER Unsafe use of the excavator while making rated lifts could cause serious potentially fatal injuries or extensive damage to the machine or nearby property Do not let anyone operate the machine unless they ve been properly trained and understand the information in the Operation and Maintenance Manual WARNING NEVER wrap a tag line around your hands or body NEVER rely on tag lines or make rated ...

Page 21: ...well if you are taking medication that makes you feel sleepy if you have been drinking or if you are suffering from emotional problems These problems will interfere with your sense of judgement in emergencies and may cause accidents When working with another operator or with a person on work site traffic duty be sure that all personnel know the nature of the work and understand all hand signals th...

Page 22: ...s cabin To ensure safety do not use the radio or music headphones when operating the machine There is danger that this may lead to a serious accident When operating the machine do not put your hands or head out of the window When standing up from the operator s seat always place safety lock lever securely in the LOCK position If you accidentally touch the work equipment levers when they are not lo...

Page 23: ... subjected is less than 2 5 m s2 Whole body The weighted root mean square acceleration to which the whole body is subjected is less than 0 5 m s2 Measurements are obtained on a representative machine using measuring procedures as described in the following standard ISO 2631 1 ISO 5349 and SAE J1166 Recommendations for Limiting Vibrations 1 Select the right machine equipment and attachments for a p...

Page 24: ...iately Always keep these parts clean Repair any damage and tighten any loose bolts Never jump on or off the machine In particular never get on or off a moving machine These actions may lead to serious injury When getting on or off the machine always face the machine and maintain three point contact both feet and one hand or one foot and both hands with the handrails steps and track shoes to ensure...

Page 25: ...nozzle in constant contact with the neck of the fuel filling nozzle to provide a ground Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured Precautions When Handling Fluids at High Temperature Immediately after operations are stopped the coolant engine oil and hydraulic oil are at high temperature and the radiator and hydraulic tank are still und...

Page 26: ...vers are operated the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury If going between movable parts is necessary always position and secure the work equipment so that it cannot move Fire Extinguisher and First Aid Kit As a precaution if any injury or fire should occur always do the following Be sure that fire extinguishers ha...

Page 27: ...rm of a FOPS Falling Object Protective Structure or window guards Never attempt to alter or modify any type of protective structure reinforcement system by drilling holes welding remounting or relocating fasteners Any serious impact or damage to the system requires a complete integrity reevaluation Reinstallation recertification and or replacement of the system may be necessary Contact your DOOSAN...

Page 28: ...lic controls to be activated Activation of any controls may enable the selected function to operate under force of gravity When performing maintenance on the pilot control system the hydraulic pressure in the system must be released as describe in Handling of Accumulator on page 4 81 The accumulator is charged with high pressure nitrogen gas so it is extremely dangerous if it is handled in the wro...

Page 29: ...or ductwork into which exhaust may be carried or blown by the wind exposing others to danger Emergency Exit This machine is equipped with a glass breaking tool It is behind the operator seat in the upper right corner of the cabin This tool can be used in case of an emergency situation that requires the breaking of glass to exit from the operator s cabin Grip the handle firmly and use the sharp poi...

Page 30: ...mage or cut any of these lines Check the condition of the river bed and the depth and flow of the water before operating in water or crossing a river NEVER be in water that is in excess of the permissible water depth Any type of object in the vicinity of the boom could represent a potential hazard or cause the operator to react suddenly and cause an accident Use a spotter or signal person working ...

Page 31: ...he machine when traveling or during operations may cause them to fall and damage or break the control levers or switches They may also get caught in the gap of the control levers and cause the work equipment to malfunction or move dangerously This may lead to unexpected accidents Check the coolant level fuel level and hydraulic tank oil level and check for clogged air cleaner and damage to the ele...

Page 32: ...ing abnormalities in the machine and this may lead to personal injury or damage to the machine Carry out the checks in an open area where there are no obstructions Do not let anyone near the machine when carrying out the checks Check the operating condition of the equipment and the actuation of the bucket arm boom travel and swing systems Check the machine for any abnormal noise vibration heat sme...

Page 33: ...Before moving the machine check the position of undercarriage The normal travel position is with idler wheels to the front under the cabin and the drive sprockets to the rear When the undercarriage is in the reversed position the travel controls must be operated in opposite directions ...

Page 34: ...ng the direction of travel Sound the horn to warn people in the area Check that there is no one in the area around the machine There are blind spots behind the machine so if necessary swing the upper structure to check that there is no one behind the machine before traveling in reverse When operating in areas that may be hazardous or have poor visibility designate a person to direct work site traf...

Page 35: ...stacle that causes the machine to tilt 10 degrees or more to the right or left or 30 degrees or more from front to rear Do not operate the steering suddenly The work equipment may hit the ground and cause the machine to lose its balance and this may damage the machine or structures in the area When traveling on rough ground travel at low speed and avoid sudden changes in direction Always keep to t...

Page 36: ... leaves or wet steel plates Even slight slopes may cause the machine to slip to the side so travel at low speed and make sure that the machine is always traveling directly up or down the slope Avoid changing the direction of travel on a slope This could result in tipping or side slipping of the machine When possible operate the machine up slopes and down slopes Avoid operating the machine across t...

Page 37: ... beforehand to prevent the machine from falling and to prevent the ground stockpiles or banks from collapsing Precautions for Operation Be careful not to go close to the edge of a cliff by mistake Use the machine only for its main purpose Using it for other purposes will cause failures To ensure an ample view do as follows When working in dark areas attach working lights and front lights to the ma...

Page 38: ... 13 20 ft from the power line Very high voltage and rainy weather could further decrease that safety margin NOTE Before starting any type of operation near power lines either above ground or buried cable type you should always contact the power utility directly and work out a safety plan with them Protecting Cabin from Falling Object Optional In a work site where falling objects or flying objects ...

Page 39: ...pacity The jolting shocks and impact loads caused by bumping or bottoming the boom or attachment are more likely to cause severe stress in very cold temperatures Reducing work cycle rate and work load may be necessary When the temperature rises frozen road surfaces become soft so the machine travel becomes unstable In cold weather do not touch metal surfaces with your bare hands If you touch a met...

Page 40: ...ads provide fences signs flags or lights and put up any other necessary signs to ensure that passing traffic can see the machine clearly and park the machine so that the machine flags and fences do not obstruct traffic After the front attachment has been lowered to an overnight storage position and all switches and operating controls are in the OFF position the safety lock lever must be set to the...

Page 41: ...anger that you may get dirt or mud in your eyes or that you may slip and injure yourself When washing the machine do the following Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your skin or having m...

Page 42: ...d explosion Fire Prevention and Explosion Prevention All fuels most lubricants and some coolant mixtures are flammable Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store oily rags and other flammable material in a protective container Do n...

Page 43: ...ali Alkali can cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Allow cooling system components to cool before you drain the cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only after the engine has been stopped Make sure that the hydraulic tank fi...

Page 44: ... fire To avoid this never subject these places to heat Do not weld on pipes or on tubes that contain flammable fluids Do not flame cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent If heat is applied directly to rubber hoses or piping under pressure...

Page 45: ...ery terminal cables 8 Reassemble the undercover under the engine 9 Reassemble the cover over the battery 10 Close the cover of the battery Warning for Counterweight and Front Attachment Removal FG000312 Figure 36 Figure 37 FG000335 1 FG000371 Figure 38 DANGER DOOSAN warns any user that the removal of the counterweight from the machine front attachment or any other part may affect the stability of ...

Page 46: ...intain a three point contact both feet and one hand or both hands and one foot to support yourself securely If the job requires it wear protective clothing To prevent injury from slipping or falling when working on the hood or covers never use any part except the inspection passage fitted with nonslip pads Lock Inspection Covers When carrying out maintenance with the inspection cover open lock the...

Page 47: ...R attempt to disassemble the track adjuster or attempt to remove the grease fitting or valve assembly Keep your face and body away from the valve Refer to the track adjustment procedure in the Operator and Maintenance Manual or Shop Manual Supports and Blocking for Work Equipment Do not allow weight or equipment loads to remain suspended Lower everything to the ground before leaving the operator s...

Page 48: ... expose your fingers Do not bend high pressure lines Do not strike high pressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly to prevent vibration rubbing against other parts and excessive heat during operation If any of the following conditions are found replace the part Damage or leakage from hose end...

Page 49: ... and may only be disposed of at approved collection facilities To prevent pollution of the environment always do the following Never dump waste oil in a sewer system rivers etc Always put oil drained from your machine in containers Never drain oil directly onto the ground Obey appropriate laws and regulations when disposing of harmful materials such as oil fuel solvent filters and batteries HAOA47...

Page 50: ...water and see a doctor at once If you accidentally drink battery electrolyte drink a large quantity of water or milk raw egg or vegetable oil Call a doctor or poison prevention center immediately When cleaning the top surface of the battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely If the battery electroly...

Page 51: ...eries connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections must be made between the nonseries connected positive terminals and between the negative terminal of the booster battery and the metal frame of the machine being boosted or charged Refer to the procedure...

Page 52: ...ight hooks and secure in position If the engine on the problem machine will not start or there is a failure in the brake system always contact your DOOSAN distributor Never go between the towing machine and the towed machine during the towing operation It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no place where the slope is gradual carry ou...

Page 53: ...icle trailer and load must all be in compliance with local regulations governing the intended shipping route Partial disassembly or teardown of the excavator may be necessary to meet travel restrictions or particular conditions at the work site See the Shop Manual for information on partial disassembly Refer to the Transportation and Shipping section of this Operation and Maintenance Manual for in...

Page 54: ... quickly The load can become unbalanced if the hook line is twisted and starts to rotate If the surface area of the load is large enough wind gusts can create side loads Figure 48 WARNING Let everybody be away from the boom cylinder While lifting operation boom arm bucket hoses might burst and then high pressure oil will be ejected at high speed If that failure mode takes place handling weight or ...

Page 55: ...forming lifting operation on a firm supporting surface An asterisk next to the lift rating indicates rated load does not exceed 87 of hydraulic capacity All other ratings have been determined not to exceed 75 of tipping capacity Do not attempt to lift or hold any load that exceeds rated load capacity at the specified distances from the machine s rotation center line and height see lift radius and ...

Page 56: ...1 50 IMPORTANT Select the Digging Mode switch on the Instrument Panel before using the excavator for lifting work Engine and hydraulic oil should both be fully warmed up to operating temperature before starting a lift ...

Page 57: ...1 77 1 77 1 86 2 00 2 33 3 02 2 04 2 39 3 10 4 36 6 41 6 57 6 58 6 42 6 08 5 54 4 73 6 10 5 57 4 78 3 53 METRIC FEET B m A m 2 3 4 5 6 MAX REACH 7 6 5 4 3 2 1 1 2 3 4 19 4 09 3 98 4 83 5 68 5 68 5 90 6 63 3 89 6 53 3 84 6 48 10 15 20 MAX REACH 20 15 10 5 5 0 GROUND 0 GROUND A ft B ft A m A ft 7 05 11 56 7 29 9 45 9 41 7 39 7 47 6 90 6 88 7 21 7 14 11 56 11 38 11 36 7 28 4 45 4 52 4 40 10 7 01 11 5...

Page 58: ... 1 66 1 77 2 03 2 54 1 81 2 08 2 45 2 88 6 82 6 97 6 98 6 83 6 51 6 01 5 24 6 53 6 04 5 32 4 24 METRIC FEET B m A m 2 3 4 5 6 MAX REACH 7 6 5 4 3 2 1 1 2 3 3 94 5 01 6 27 4 55 3 74 4 14 4 4 22 4 11 3 99 4 31 4 25 4 25 5 38 6 57 3 88 6 52 3 82 6 45 10 15 20 MAX REACH 20 25 15 10 5 5 0 GROUND 0 GROUND A ft B ft A m A ft 7 04 10 67 7 32 8 03 8 44 7 52 7 52 6 84 6 79 7 20 7 11 11 56 11 33 11 27 7 30 4...

Page 59: ... 41 7 28 6 98 6 52 5 85 6 99 6 54 5 88 4 93 METRIC FEET B m A m 2 3 4 5 6 2 64 2 66 2 68 2 70 1 63 1 65 1 67 1 68 7 MAX REACH 7 6 5 4 3 2 1 1 2 3 3 91 6 48 6 21 4 70 2 91 4 88 4 3 61 4 24 4 10 3 61 5 76 5 76 4 74 5 99 3 96 6 61 3 87 6 51 10 15 20 MAX REACH 20 25 15 10 5 5 0 GROUND 0 GROUND A ft B ft A m A ft 7 23 9 61 7 56 6 63 7 31 6 63 7 31 6 97 6 86 7 37 7 25 11 76 11 46 11 34 7 51 4 60 4 73 7 ...

Page 60: ...1 97 1 98 2 07 2 23 2 59 3 33 2 27 2 65 3 41 4 36 6 41 6 57 6 58 6 42 6 08 5 54 4 73 6 10 5 57 4 78 3 53 METRIC FEET B m A m 2 3 4 5 6 MAX REACH 7 6 5 4 3 2 1 1 2 3 4 58 4 49 4 37 4 83 5 68 5 68 5 90 6 58 4 29 6 47 4 24 6 42 10 15 20 MAX REACH 20 15 10 5 5 0 GROUND 0 GROUND A ft B ft A m A ft 7 78 11 56 8 02 9 45 9 41 8 12 8 19 7 62 7 60 7 14 7 07 11 45 11 28 11 25 7 21 4 96 5 02 4 90 10 7 74 11 4...

Page 61: ... 1 98 2 26 2 82 2 02 2 25 2 45 2 88 6 82 6 97 6 98 6 83 6 51 6 01 5 24 6 53 6 04 5 32 4 24 METRIC FEET B m A m 2 3 4 5 6 MAX REACH 7 6 5 4 3 2 1 1 2 3 4 33 5 01 6 86 7 27 4 55 4 11 4 14 4 4 31 4 51 4 38 4 31 4 25 4 25 5 38 6 57 4 27 6 46 4 21 6 39 10 15 20 MAX REACH 20 25 15 10 5 5 0 GROUND 0 GROUND A ft B ft A m A ft 7 76 10 67 8 04 8 03 8 44 8 03 8 24 7 57 7 51 7 12 7 03 11 45 11 22 11 16 7 23 4...

Page 62: ...4 7 27 7 41 7 41 7 28 6 98 6 52 5 85 6 99 6 54 5 88 4 93 METRIC FEET B m A m 2 3 4 5 6 7 MAX REACH 7 6 5 4 3 2 1 1 2 3 4 30 6 48 6 80 8 69 12 22 12 22 4 68 3 21 4 88 4 3 61 4 63 4 49 3 61 5 76 5 76 5 12 5 12 4 74 5 99 4 36 6 55 4 26 6 45 10 15 20 MAX REACH 20 25 15 10 5 5 0 GROUND 0 GROUND A ft B ft A m A ft 7 95 9 61 8 28 6 63 7 31 6 63 7 31 7 69 7 59 7 30 7 17 11 65 11 36 11 23 7 44 5 11 5 23 7 ...

Page 63: ...23 2 86 2 86 3 23 3 23 6 85 7 00 7 00 6 86 6 54 6 05 6 56 6 07 5 36 4 29 METRIC FEET B m A m 3 4 5 6 7 MAX REACH 7 6 5 4 3 2 1 1 2 2 89 2 82 2 74 3 67 4 08 4 08 4 29 4 52 2 68 4 45 2 64 4 40 3 71 6 38 10 15 20 MAX REACH 20 15 10 5 5 0 GROUND 0 GROUND A ft B ft A m A ft 6 86 10 08 7 20 6 76 7 58 6 76 7 49 6 67 6 65 7 16 7 06 11 44 11 22 11 19 7 28 4 35 4 46 7 33 4 51 7 05 4 25 4 26 11 87 11 87 5 63...

Page 64: ...4 2 33 1 58 1 81 2 20 3 01 7 22 7 36 7 37 7 23 6 93 6 47 5 40 6 95 6 49 5 83 4 86 METRIC FEET B m A m 3 4 5 6 7 MAX REACH 7 3 50 3 50 3 35 8 6 5 4 3 2 1 1 2 3 2 91 2 83 2 75 3 31 3 56 3 56 4 06 4 71 4 10 4 10 3 94 4 53 2 67 4 44 2 62 4 38 10 15 20 MAX REACH 20 15 10 5 5 0 GROUND 0 GROUND A ft B ft A m A ft 6 86 9 17 7 24 5 72 6 68 5 72 6 68 6 62 6 55 7 14 7 02 11 45 11 17 11 10 7 30 4 33 4 47 6 90...

Page 65: ...11 Seat Adjustment on page 2 61 12 Ceiling Cover on page 2 65 13 Front Windows on page 2 66 14 Door Side Latch on page 2 68 15 Cabin Storage Compartments on page 2 69 16 Ashtray on page 2 69 17 Sun Visor on page 2 70 18 Hanger on page 2 70 19 Cup Holder on page 2 71 20 Door Window Holder on page 2 71 21 Emergency Glass Breaking Tool on page 2 71 22 Miscellaneous Access Covers and Doors on page 2 7...

Page 66: ...ntrols 2 2 WARNING Warning lights When any one or more of the warning lights on the control console comes ON immediately stop operation and shut down unit Investigate and correct the problem before proceeding with operation ...

Page 67: ...OP000597 2 3 Operating Controls ...

Page 68: ...OP000597 Operating Controls 2 4 COMPONENT LOCATIONS Figure 1 FG009601 18 17 16 15 13 14 12 11 10 9 8 7 6 5 4 3 2 1 38 37 36 35 34 33 32 31 30 29 28 27 19 25 26 24 23 22 21 20 ...

Page 69: ...wing Bearing 13 Seat 14 Cabin 15 Boom Cylinder 16 Work Lever Joystick Controls 17 Arm Cylinder 18 Boom 19 Travel Lever 20 Arm 21 Bucket Cylinder 22 Guide Link 23 Bucket 24 Push Link 25 Tooth Point 26 Side Cutter 27 Idler 28 Track Adjuster 29 Track Guide 30 Battery 31 Lower Roller 32 Center Joint 33 Upper Roller 34 Track Link and Shoe 35 Travel Motor 36 Sprocket 37 Suction Filter 38 Return Filter 3...

Page 70: ...OP000597 Operating Controls 2 6 OPERATOR S AREA 1 3 2 5 4 9 8 7 6 10 11 19 20 16 15 14 13 12 17 18 21 FG009720 Figure 2 ...

Page 71: ... Heater and Air Conditioner Control Panel See page 2 51 9 Starter Switch See page 2 10 10 Seat See page 2 61 11 Storage Compartment See page 2 69 12 Heater and Air Conditioner Unit 13 Stereo See page 2 57 14 Fuse Box See page 2 60 15 Left hand Work Lever Joystick See page 3 23 16 Safety Lever See page 3 13 17 Storage Compartment See page 2 69 18 DMS Laptop Computer Connector 19 Cup Holder See page...

Page 72: ...OP000597 Operating Controls 2 8 OPERATIONAL CONTROLS AND PANELS 16 27 14 13 12 11 10 9 8 6 15 25 7 1 2 3 5 4 24 23 20 19 18 17 26 21 22 FG009721 Figure 3 ...

Page 73: ... Cabin Work Light Switch Optional 11 Warning Light Switch Optional 12 Lower Wiper Switch Optional 13 Heater And Air Conditional Control Panel 14 Wiper Control Panel 15 Cigarette Lighter 16 Power Socket For 12v 17 Travel Swing Alarm Switch Optional 18 Overload Warning Switch Optional 19 Fuel Heater Switch Optional 20 Seat Warmer Switch Optional 21 Horn Button 22 Rotating Switch 23 Breaker Booster S...

Page 74: ...e engine preheat cycle is completed The preheat cycle takes about twenty seconds to complete and the indicator light will turn OFF When the light turns OFF engage the starter Moving switch to this position will crank engine When engine starts release key and allow it to return to the I ON position Do not operate the starter switch for more than fifteen seconds at a time This will help prevent dama...

Page 75: ...arm I In this position the quick clamp is UNLOCKED The attachment is released from the arm NOTE To move the switch pull up on the toggle and then move it into the UNLOCKED position FG001342 O I Figure 6 WARNING When the attachment is still connected to the machine while the switch is I position do not operate the machine or the attachment might fall to the ground It would cause personnel injuries ...

Page 76: ...d by moving the engine emergency stop switch to the I EMERGENCY STOP position O In this position the engine emergency stop system is OFF I In this position EMERGENCY STOP is selected The engine will shut down NOTE When released the switch will return to its original position O OFF position 6 Audio Control Panel The audio system can be remotely controlled using this panel FG001343 O I Figure 7 CAUT...

Page 77: ...on to DECREASE volume Manual Scan When pressing scan button once for less than half a second the frequency will be moved up in sequence to the next available signal Auto Scan When pressing scan button for more than a half a second the frequencies are automatically scanned to the next higher one and will continue until the button is again pressed to stop the scan FG000019 PWR Figure 10 FG000020 Fig...

Page 78: ...ht Switch This switch is used to turn ON the lights O In this position all lights are OFF I In this position all illumination lights of the instrument panel and the control switches are turned ON II In this position all illumination lights and work lights are turned ON FG000023 O I II Figure 14 WARNING Do not operate the travel speed selector switch when unit is in motion Temporary loss of control...

Page 79: ...tion the front cabin work lights on the front top of cabin will turn ON II In this position the front cabin work lights on the front top of cabin and rear cabin work lights on rear top of cabin will turn ON 11 Warning Light Switch Optional If unit is equipped with a warning light push this switch to activate it O In this position the warning light is turned OFF I In this position the warning light...

Page 80: ... Heater and Air Conditioner Control Panel This panel is used to control air conditioner and heater in operator s compartment Refer to Heater and Air Conditioner Control Panel on page 2 51 for more details 14 Wiper Switch Panel This panel is only for operation of the upper windshield wiper When the wiper stops running it moves to right side of the cabin resting in its support NOTE When the front wi...

Page 81: ...econd intermittent cycle The right side indicator light will turn ON Pressing button again third time Turns OFF the windshield wiper Both indicator lights will be turned OFF Windshield Washer Button Pressing the washer button will spray windshield washer fluid onto the windshield Use only the proper windshield washer fluid in the system NOTE Do not operate the windshield washer without any fluid I...

Page 82: ...is designed for small electrical capacity devices Do not use this socket for large electrical capacity devices Thus damage can be avoided 17 Travel Swing Alarm Switch Optional If unit is equipped with a travel swing alarm buzzer push this switch to active it whenever swinging or traveling O In this position the travel swing alarm system is turned OFF I In this position the travel alarm will only s...

Page 83: ...O In this position the fuel heater system is turned OFF I In this position the fuel heater system is turned ON NOTE The starter switch must be ON 20 Seat Warmer Switch Optional If the seat is equipped with the optional seat warmer push this switch to activate it When the seat is warmed the warmer is automatically turned OFF O In this position the seat warmer is turned OFF I In this position the se...

Page 84: ...lockwise and the right one is for clockwise 23 Booster Button Right hand Work Lever Press the lower button on the top of the right hand work lever joystick to boost the hydraulic pressure Refer to the Boost Mode on page 3 22 NOTE This button works with the breaker boost shear selector switch See 9 Breaker Boost Shear Selector Switch on page 2 15 Figure 31 FG002084 Figure 32 FG000382 WARNING Before...

Page 85: ...9 Breaker Boost Shear Selector Switch on page 2 15 25 Instrument Panel See Instrument Panel on page 2 24 26 Safety Lever See Safety Lever on page 3 13 Figure 34 FG000383 WARNING Before using any attachment in a work application be sure to check its functional control Make sure that the desired movement or action is being activated by the control e g opening closing CW CCW crowd dump etc C H E F H ...

Page 86: ...ontrols 2 22 27 Photo Sensor The photo sensor detects the radiant energy of the sun In auto mode the air conditioner will automatically adjust the air temperature based on to the detected radiant energy FG000399 Figure 37 ...

Page 87: ...OP000597 2 23 Operating Controls ...

Page 88: ...OP000597 Operating Controls 2 24 INSTRUMENT PANEL C H E F H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 FG000039 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 7 8 9 10 11 12 5 1 2 15 13 14 3 4 17 19 20 16 18 6 Figure 38 ...

Page 89: ...lock on page 2 45 for further details CAUTION If the password does not match the stored password the engine will not start Reference Number Description 1 Fuel Gauge 2 Engine Coolant Temperature Gauge 3 Hydraulic Oil Temperature Gauge 4 Multifunction Gauge And Graphic Information Area See page 2 31 5 Digital Clock 6 Hour Meter 7 Charge Warning Light 8 Engine Oil Pressure Warning Light 9 Engine Cool...

Page 90: ...in the normal operating range RED ZONE Indicates temperature is too high During operation the pointer must be in the blue zone If the gauge pointer moves into the red zone the engine coolant temperature warning light will turn ON a warning buzzer will sound and the engine speed will be automatically reduced Allow the engine to run at low idle speed until the temperature gauge registers in the blue...

Page 91: ...ne to run at low idle speed until the temperature gauge registers in the blue zone again NOTE See Abnormal State Warning Symbols on page 2 33 for location of this warning symbol and others 4 Multifunction Gauge and Graphic Information Area See Multifunction Gauge and Graphic Information on page 2 31 This section will have a more in depth explanation of the display area 5 Digital Clock A digital cl...

Page 92: ...ately and determine the cause of the problem 8 Engine Oil Pressure Warning Light This indicator light will turn ON when the engine starter switch is turned ON and should go OFF after the engine starts For example if the engine oil pressure becomes too low the light will turn ON and a warning buzzer will sound If this happens shut the engine down immediately and determine the cause of the problem I...

Page 93: ...ically reduced Allow the engine to run at low idle speed until the temperature gauge registers in the blue zone again When the blue zone is reached allow the engine to idle for an additional three five minutes before shutting down the engine If not allowed to idle heat surge may develop which will damage the engine Allowing the engine to idle will dissipate heat Check the coolant level look for a ...

Page 94: ...ight indicates that the engine preheat function is operating When this indicator light turns OFF it means that the engine preheat cycle has been completed 12 Work Light Indicator Light The indicator light indicates that the work lights are turned ON HAAE2000 Figure 49 HB4O2003 Figure 50 ...

Page 95: ...Rear pump pressure BAR NOTE See Figure 54 thru Figure 57 A digital clock is located at the top of the display By using a combination of the mode selector buttons information for filters and oils can also be displayed The display can also be set for the desired language Refer to the Setting Main Menu on page 2 38 for the language selection and information display sequences Communication Indicator I...

Page 96: ...h is turned to the I ON position during a state of communication error failure the e EPOS controller will default to the following modes Power mode Standard mode Working mode Digging mode Auto idle ON Selection state Engine Speed The engine speed is numerically displayed Battery Voltage The battery voltage is numerically displayed With the engine running the reading should be between 26V 30V When ...

Page 97: ...rically displayed NOTE This pump is the farthest from engine flywheel housing or is the lower one of hydraulic pump It displays the reading in BARs Abnormal State Warning Symbols 1 Hydraulic Oil Overheating Warning 2 Pilot Filter Clogged Warning 3 Fuel Shortage Warning 4 Return Filter Clogged Warning 5 Air Cleaner Clogged Warning 6 Overload Warning Optional FRONT PUMP 320 BAR FG000051 Figure 56 RE...

Page 98: ... If this symbol is displayed immediately stop operation and replace the pilot filter After the pilot filter has been serviced restart machine operation to remove the warning symbol C H C E F H E G SPEED 1700 RPM FG000059 02 05 MO 11 30 C H C E F H E G SPEED 1700 RPM FG000060 02 05 11 30 C H C E F H E G SPEED 1700 RPM FG000061 2 kinds of warning display 4 kinds of warning display 6 kinds of warning...

Page 99: ...s displayed immediately stop operation and replace the return filter After the return filter has been serviced restart machine operation to remove the warning symbol 5 Air Cleaner Clogged Warning This symbol indicates when the air cleaner is clogged If this symbol is displayed immediately stop operation and replace or clean the air filter After the air filter has been serviced restart machine oper...

Page 100: ...N or OFF When the power mode button is pushed to the ON position an indicator light above it turns ON When the power mode button is pushed again it is turned OFF and the power mode is deactivated and returns to the standard operating mode When turning the engine starter switch to the I ON position the power mode is automatically defaulted to Standard Mode NOTE For further details see Mode Selectio...

Page 101: ...matically reduce speed to IDLE approximately four seconds after all of the control levers are in the neutral position This system is designed to reduce fuel consumption and noise When the auto idle selector button is pushed to the ON position an indicator light above it turns ON When the auto idle selector button is pushed again it is turned OFF and the engine speed will return to the setting of t...

Page 102: ... display screen Items such as language time and filter oil information can be checked and if necessary set with new information 1 Up Arrow Button Up arrow button is used to move a menu item Up or to the Left C H C E F H 02 05 MO 11 30 E G SPEED 1700 RPM FG000043 Figure 71 1 5 POWER 3 2 6 7 AUTO 4 ESC 8 FG001339 4 3 2 1 Figure 72 FG000068 3 Figure 73 ...

Page 103: ...sed the digital readout changes NOTE When setting the main menu this button is used as the menu exit button ESC To access the menus the button must be pressed and held for three seconds NOTE When this button is used for menu exit button it is used to access to main menu or return to a previous screen from each submenu 4 Selection Button Selection button is used to set a menu or clear the operating...

Page 104: ... any menu without changing the screen it will return to the normal display screen Main Menu The menu selection can be changed by pressing the UP or DOWN buttons The selected menu item will be highlighted and a cursor will appear by the menu item When the selected menu item is highlighted press the SELECT button to enter the next submenu 1 Language on page 2 41 2 Set Clock on page 2 41 3 Filter Oil...

Page 105: ... clock submenu will appear NOTE If more than twenty seconds are spent in the menu without changing the screen it will return to the normal display screen Setting Method 1 Move the cursor to desired number by using the SELECT button When selected the number will flash 2 Set the time by using the UP or DOWN buttons Increase or decrease number MOVE Confirm and move the cursor to next number ESC Exit ...

Page 106: ... will be increased Filter Oil Info When the cursor is on Filter Oil Info press the SELECT button The filter oil information submenu will appear Each symbol can be selected by pressing the UP or DOWN buttons At the bottom of the screen the operating hour Hrs of each filter and or oil is displayed SET CLOCK MOVE FG000076 06 05 2004 06 29 Figure 83 MAIN MENU 1 Language 4 Adjust Display 5 Set Password...

Page 107: ...d to zero hour Hrs 0000 by pressing the SELECT If the SELECT button is pressed the reset will be completed and the screen will be returned to the previous menu If the ESC button is pressed the screen will be returned to the previous menu without being reset NOTE If more than twenty seconds are spent in the menu without changing the screen it will return to the normal display screen The screen is r...

Page 108: ...an be selected by using UP or DOWN buttons NOTE When the equipment shipped the default brightness is set to 50 The screen is returned to the main menu by pressing the ESC button The display is then saved MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000080 Figure 88 Adjust Display FG000081 50 LCD TEST LCD TEST LCD TEST Figure 89 ...

Page 109: ...es Example 2785 is acceptable 9024 is not acceptable When the cursor is on Set Password press the SELECT button The set password submenu will appear NOTE The screen can be returned to the main menu by pressing the ESC button 3 Figure 72 Password inquiry menu will be displayed NOTE The initial password is 1111 The password can be changed within ten minutes while the starter switch is in I ON positi...

Page 110: ...on unlock the password function will be in working or nonworking When you want to change a password follow below procedure 1 Move the cursor to Change Password 2 Input desired 4 digits password using selector buttons at the first column Input the same password one more time at the second column 3 Select adoption lock or nonadoption unlock at set password menu NOTE Keep in mind never to forget pass...

Page 111: ...ton Figure 70 and Figure 95 is pressed at the normal display screen Figure 94 the flow control screen Figure 97 will be displayed Select a tool by using the breaker boost shear selector switch The symbol in the upper left corner of the display screen will change according to the position that the selector switch is in Compare the symbols shown in Figure 97 and Figure 98 Figure 94 C H C E F H 02 05...

Page 112: ...in engine rpm Escape A Press flow control button Figure 95 to return to normal display screen and save the flow rate setting B If there is no adjustment for twenty seconds the flow control screen will return to the normal display screen FLOW CONTROL ESC CANCEL FG000254 APPLY Figure 97 Breaker Flow Control Step Pump Flow Setting l min 0 48 5 1 57 2 66 3 69 4 78 5 5 90 6 96 5 7 106 5 8 108 9 114 10 ...

Page 113: ... application that is currently selected Power Boost Selection Breaker Selection Shear Selection Figure 100 C H C E F H 02 05 MO 11 30 E G SPEED 1700 RPM FG000257 Figure 101 C H C E F H 02 05 MO 11 30 E G SPEED 1700 RPM FG000258 Figure 102 C H C E F H 02 05 MO 11 30 E G SPEED 1700 RPM FG000259 ...

Page 114: ...Controls 2 50 Overload Alarm Selection Optional Quick Clamp Operation Selection Optional Figure 103 C H C E F H E G SPEED 1700 RPM FG000260 02 05 MO 11 30 Figure 104 C H C E F H E G SPEED 1700 RPM FG000388 02 05 MO 11 30 ...

Page 115: ...ONTROL PANEL Location of Controls and Vents The heater and air conditioner are combined into one unit in the rear cover behind the operator s seat The operator can control cabin temperature using the control panel installed in the switch panel Figure 105 FG000288 ...

Page 116: ... the system is in AUTO mode specifications can be manually changed by pushing another button If a function is manually changed the word AUTO does not appear in the LCD display but the unchanged functions will remain in AUTO mode AUTO AUTO OFF TEMP A C A C MAX OUTSIDE SEL MODE 1 3 10 7 8 9 6 5 4 2 FG000086 Figure 106 Reference Number Description 1 Automatic Temperature Control Button 2 Off Button 3...

Page 117: ...perature Temperature is adjustable from 17 C 62 F to 32 C 90 F by 0 5 C 1 F increments Temperature setting is displayed on the LCD When the system is turned ON the previously set temperature is used as a starting point 4 Temperature Unit Selector Button This button gives the choice to select either C or F OFF FG000089 Figure 108 Figure 109 TEMP FG000090 SEL FG000094 Figure 110 ...

Page 118: ... the front and rear B Used to direct air flow to upper portion of operator s cabin from both the front and rear It will also deliver air to the lower portion of operator s cabin from under the operator s seat C Used to direct air flow to lower portion of operator s cabin and feet This mode is mainly used for heating MODE FG000096 Figure 111 FG000099 Figure 112 FG000097 Figure 113 FG000100 Figure 1...

Page 119: ...Draws fresh air into operator s compartment Used to exchange air within the operator s compartment with fresh air Used to remove condensation or ice on window Winter Rainy Season B B Symbol Recirculates air within the operator s compartment Used to quickly warm or cool the operator s cabin 7 Fan Speed Selector Buttons These buttons are used to control the speed of the blower fan Momentarily pressi...

Page 120: ...ngs for the panel will be stored When the excavator is started the last stored setting will be used Additional Operating Instructions A proper indoor temperature in summer is 5 6 C 10 12 F less than the outdoor temperature Operate the air conditioner for twenty thirty minutes a week to circulate the refrigerant in the system NOTE The blower button should be on Three Bars If operating the air condi...

Page 121: ... N H O F F O SOUND TUNE L AM FM 1 4 3 2 5 6 SCAN PROGRAM AST FG000108 2 3 7 9 8 5 6 10 4 1 Figure 122 Reference Number Description 1 Power Volume Control 2 Sound Mode Selector 3 Band Selection 4 Tuning Up Down 5 Scan Function Auto Store 6 Preset Station 7 Tape Ejection 8 Fast Forward Rewind 9 Tape Loading Slot 10 LCD Reference Number Description ...

Page 122: ...OP000597 Operating Controls 2 58 CD Player Optional AST DIR FG000109 Figure 123 ...

Page 123: ...s the work and travel levers With the work and travel levers deactivated no digging operational work can be done Circuit Breaker A main circuit breaker is in the battery box It will automatically cut off in case of an electrical short circuit or overload This will prevent the electric wiring and components from being burned or damaged If the circuit breaker is cut off check all related circuits th...

Page 124: ...attached to the inside of the fuse box access cover indicates the function and amperage of each fuse NOTE For a further explanation see Fuse Boxes on page 2 60 Spare fuses are mounted on the inside of fuse box access cover Change a fuse if the element separates If the element of a new fuse separates check the circuit and repair the circuit HAAE2120 A Figure 127 WARNING When changing the fusible li...

Page 125: ...ht It is possible to move the seat up or down by combining adjustments forward and rear tilt Adjust the seat according to operator s size and work conditions Height adjustment is 60 mm 2 4 in 3 Suspension Adjustment Turning knob 3 Figure 129 to right makes the suspension harder Turning knob to left makes the suspension softer Adjust according to operator s weight by checking the weight indicator d...

Page 126: ...justed forward backward and up down Move it by holding both sides 8 Seat Belt Figure 130 5 8 6 9 7 FG000778 WARNING The seat belt is for the operator s safety and should always be worn Before driving the machine adjust the seat to the desired position for maximum comfort and machine control then fasten the seat belt Seat belts must be worn across the pelvic region and adjusted snugly to lessen the...

Page 127: ...ntenance manual 10 Left and Right Control Stand Adjustment For operator s convenience the right and left control stands and seat can slide together within a 160 mm 6 3 in forward or backward travel distance Holding lever 10 Figure 133 raise it up set the seat to desired position Release lever to lock the seat in the selected position 11 Left and Right Control Stand Height Adjustment The left and r...

Page 128: ...ed to adjust the air cushion If the switch is pressed the seat become harder and pulling it out makes the seat softer when the air is bleed out 13 Heating the Operator s Seat Optional The air suspension seat can be heated The switch on the left control stand is used to warm the seat When heating is not needed or seat is warmed turn the switch to OFF position FG000187 12 Figure 134 FG000034 O I Fig...

Page 129: ...it with a soft fabric towel Opening the Ceiling Cover 1 Lower bucket to ground 2 Set safety lever Figure 136 on LOCK 3 Pull the lock 1 Figure 137 in front center of ceiling cover and push it up with handle Closing the Ceiling Cover 1 Lower bucket to ground 2 Set safety lever Figure 136 on LOCK 3 Pull down cover with the handle Figure 137 so that the lock 1 can be locked in the bracket in the ceili...

Page 130: ... lock pin at the rear of the cabin Make sure that it is securely latched 7 Check that lock levers are securely latched in the lock position NOTE When the front upper window is open never extend your head or body through the window frame NOTE If the window happens to fall with a strong impact against the machine while some part of your body is extended out of the cabin it may result in bodily injur...

Page 131: ...securely latched in the lock position Front Bottom Window The front bottom window can be removed and stored in the rear of the cabin 1 After stowing the front upper window in the cabin ceiling remove bottom window 1 Figure 141 from cabin in direction of the arrow 2 Set bottom window in rubber holders 2 Figure 142 behind operator s seat Secure window with left and right knobs 3 with push button 4 1...

Page 132: ...secured the door to the side of the cabin when it is opened NOTE Keep the door closed and locked when machine is not in use 2 To release door from side of cabin push the latch lever 2 Figure 144 down The latch lever is to the left of the operator s seat 1 FG000196 Figure 143 2 FG000673 Figure 144 ...

Page 133: ...is interconnected with the air conditioner So it can be supplied with either warm or cool air when air conditioner is turned ON There is a separate small tray 3 Figure 146 on the right side of operator s seat ASHTRAY An ashtray 1 Figure 147 is to the right side of the operator s seat on the side of the cabin Always close ashtray after putting out a cigarette FG000209 2 1 Figure 145 3 FG000675 Figu...

Page 134: ...E Do not allow the visor to roll back up without holding it Not holding it may result in damage to the visor and retract mechanism Ceiling sun visor 3 Figure 149 slides forward and backwards Move it with handle 4 on each side When opening the ceiling cover if equipped push the sun visor into its compartment Figure 150 HANGER A hanger 1 Figure 151 is located on the upper left side of the operator s...

Page 135: ... be reduced by tightening knob 1 Figure 153 against the window EMERGENCY GLASS BREAKING TOOL The excavator is equipped with a glass breaking tool It is to the upper right corner of the cabin This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the cabin Grip the handle firmly and use the sharp point to break the glass 1 FG000205 Figure 152 1 FG0...

Page 136: ...pen door until locking device 1 Figure 156 latches Closing While holding door press locking device to release lock and close door Engine Cover Open the cover and slide prop rod 1 Figure 157 in the slot 2 until it locks in notch at the end of slot to support the cover To close cover move end of prop rod out of notch so it can slide in slot FG000165 1 2 Figure 155 FG006301 1 Figure 156 FG000167 2 1 ...

Page 137: ...kage of coolant fuel engine oil and hydraulic oil 2 Inspect all lubricants daily add appropriate lubricants as required 3 During operation monitor all instruments and gauges from time to time 4 Avoid an extreme engine load 5 Operate unit at 80 load until engine and all other components are at operating temperature 6 Check that work equipment is operating normally during operation 7 Check machine f...

Page 138: ... fuel tank and water separator 3 Hydraulic system Check for hydraulic oil leaks damaged tubing and hoses and interference points of components 4 Lubrication Perform all daily and periodic maintenance services Perform services according to reading shown on hour meter 5 Safety Perform a machine walk around Make sure that no one is under the machine or performing any maintenance on it before starting...

Page 139: ...l sound for about two seconds After two seconds all lights except the following will turn OFF Charging warning light Engine oil pressure warning light Engine coolant temperature gauge Fuel gauge Hydraulic oil temperature gauge Engine rpm 0 rpm digital readout NOTE If all of the indicator lights do not come ON when the key is first turned there is a problem FG000211 Figure 1 WARNING When leaving op...

Page 140: ...r switch to START position Figure 5 Engine should start in approximately five seconds 6 After engine has started release key Key will return to the I ON position Figure 5 7 Follow procedures in Hydraulic System Warm up on page 3 9 WARNING Start the engine after sounding horn and making sure that there are no people or obstacles in the area HAOB34L Figure 3 C H C E F H 02 05 MO 11 30 E G SPEED 0 RP...

Page 141: ... the engine speed will be automatically reduced Allow the engine to run at low idle speed until the temperature gauge registers in the blue zone again When the blue zone is reached allow the engine to idle for an additional three five minutes before shutting down the engine If not allowed to idle heat surge may develop which will damage the engine Allowing the engine to idle will dissipate heat Ch...

Page 142: ... IDLE Figure 7 3 Sound horn 4 Turn starter switch to the I ON position Figure 8 When preheat cycle is completed the preheat indicator light 1 Figure 9 will turn OFF WARNING DO NOT USE STARTING FLUIDS The preheat system could cause the starting fluid to explode Starting fluids should never be used HAOB34L Figure 7 FG000084 O I Figure 8 FG000217 1 CHECK Figure 9 ...

Page 143: ...five minutes and repeat above step HAOA440L Figure 11 WARNING 1 An explosive gas is produced while batteries are in use or being charged Keep flames or sparks away from the battery area 2 Charge batteries in a well ventilated area 3 Always wear eye protection when starting a machine with jumper cables 4 Improper jump starting procedures can cause an explosion resulting in personal injury 5 Jump st...

Page 144: ... the machine to be started with the other end of black cable 2 Figure 12 When making the last connection to upper frame be sure to connect the cable end as far away from the machine batteries as possible DO NOT CONNECT DIRECTLY TO THE NEGATIVE BATTERY TERMINAL 4 Start the engine Disconnecting the Booster Batteries 1 Disconnect black negative cable 2 Figure 12 from the machine frame 5 first 2 Disco...

Page 145: ...m and bucket cylinders about five times without a load to circulate the oil through the system Do this for five minutes 4 Check for clearance and fully raise the front attachment Swing clockwise 3 revolutions Swing counterclockwise 3 revolutions 5 Travel forward and reverse at low speed for two revolutions of the drive sprocket WARNING If a problem or abnormal operation occurs immediately shut dow...

Page 146: ...tely five minutes set at the middle of the speed range without a load Figure 17 3 Set safety lever 1 Figure 18 on UNLOCK position 4 Slowly cycle boom arm and bucket cylinders about five times without a load to circulate the oil through the system Do this for five minutes HAOB290L Figure 16 HAOB410L Figure 17 FG000093 1 Figure 18 Figure 19 FG000380 ...

Page 147: ... two revolutions of the drive sprocket Engine Shut Down NOTE Allow engine to idle for three five minutes before shutting down the engine If not allowed to idle heat surge may develop which will damage the engine Allowing the engine to idle will dissipate heat 1 Park excavator on level and firm ground 2 Lower front end attachment to ground and make sure all operating controls are in NEUTRAL 3 Set s...

Page 148: ...y coolant or oil leaks 2 Inspect front attachment and under carriage for abnormal appearances Correct any problems 3 Fill fuel tank 4 Get rid of any accumulated flammable materials such as leaves and paper etc in engine compartment 5 Clean all mud etc from undercarriage and tracks Make sure that all steps and hand holds are clean and that the operator s compartment is clean FG000390 O I Figure 24 ...

Page 149: ...ork NOTE When the engine is not running but the safety lever is RELEASED and the starter key is tuned ON moving the work levers joysticks may result in movement The charged accumulators in the system will provide pilot pressure for control valve spool movement WARNING When stopping engine or leaving the operator s seat LOCK the safety lever otherwise a serious accident may occur by accidental move...

Page 150: ... while sitting in the operator s seat you are looking at the back end of the track assembly therefore you are looking backwards In this case the response of the travel levers will be the reverse of normal operation 2 Before moving make sure that there are no personnel in the way or on the machine Sound the horn to alert workers that you are about to move the machine 3 Be sure the path is clear dur...

Page 151: ...achine is traveling on a flat solid surface the higher speed range would be used When a slope is encountered the speed drops and the travel circuit hydraulic pressure rises causing the control circuit to shift to the higher torque lower speed range ...

Page 152: ... backward The machine will pivot on the nonmoving track NOTE X is the sprocket end of the track 3 Spin turns Figure 29 are made by rotating one track forward and one track backward The machine will spin around its center point thus counterrotating NOTE X is the sprocket end of the track 4 Stopping travel Figure 30 Returning travel levers to NEUTRAL position will automatically apply brakes and stop...

Page 153: ... ground See Figure 32 3 When possible travel on firm level ground Avoid sudden movements and sharp turns 4 When traveling on rough ground travel at a slow speed 1 0 1 5 km h 0 62 0 93 MPH Reduced engine speed to avoid shock loading the equipment Be careful that an excessive force is not added to equipment by touching or climbing on rocks HAOB550L Figure 31 FG000123 40 50 cm Figure 32 Figure 33 FG0...

Page 154: ...212 Figure 34 Figure 35 FG000126 20 30 Cm WARNING When traveling keep bucket from 20 30 cm 8 12 in above ground Do not travel backward on a slope Never turn or travel crosswise on a slope Choose a safe alternate route before climbing a slope If excavator starts to slip or becomes unstable lower the bucket immediately into the ground using it as a brake Avoid working on slopes because there is a da...

Page 155: ...id so that the machine will not sink See Working in Water on page 3 31 NOTE If the machine is submerged to the point that water or mud gets into the swing bearing or center joint stop machine operation Remove the machine from the submerged location to firm dry ground Do not operate until proper inspection and maintenance have been completed Refer to the Shop Manual or contact your distributor Figu...

Page 156: ...a proper power mode using button 1 Figure 40 before starting work 3 When the power mode button 1 Figure 40 is pressed a signal sounds changing the power mode to either ON or OFF When the power mode is turned ON the LED indicator 2 Figure 40 turns ON Deactivate the power mode by pressing it a second time When the power mode is turned OFF the LED indicator 2 Figure 40 turns OFF and the power mode re...

Page 157: ...e neutral position When a pilot function is activated engine speed is automatically returned to the preselected range 2 When the starter switch is turned ON the work mode is automatically defaulted to AUTO IDLE 3 When the LED indicator 6 Figure 42 is turned ON the auto idle function is activated Deactivate the auto idle function by again pressing the auto idle selector button 5 Figure 42 At this t...

Page 158: ...le the lower button is being pressed on top of the right hand work lever joystick The breaker boost shear selector switch must be in the O BOOST position NOTE The power boost mode does not affect forward and reverse travel Do not use this switch for more than ten seconds FG000117 O I I I Figure 43 RIGHT HAND WORK LEVER JOYSTICK ...

Page 159: ...Arm crowd 3 Left swing 4 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 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 weight of the arm may cause it to move...

Page 160: ...attachment The machine control pattern can easily be changed to the ISO standard or to the standard backhoe loader hydraulic system BHL by changing the position of the select valve if equipped Use the following procedure to change the position of the select valve The select valve is located in the rear of the cabin 1 Rotating spool to the ISO position or to the BHL position Figure 49 FG000121 6 5 ...

Page 161: ...gure 51 5 Arm dump 6 Arm crowd 7 Bucket crowd 8 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 weight of the arm may cause it to move faster than the amount of oil being supplied NOTE Even after stopping the engine the front can be lowered to the ground by operating ...

Page 162: ...o raise blade pull lever backwards Whenever dozer blade is being used to level ground make sure to set travel speed control to LOW SPEED Attempting to use dozer blade in HIGH SPEED will cause damage to drive system 9 Blade down 10 Blade up Two Piece Boom Optional 11 Upper Boom down 12 Upper Boom up 9 10 FG009722 Figure 53 9 10 FG009730 Figure 54 12 FG009728 11 Figure 55 12 FG009729 11 Figure 56 ...

Page 163: ... unit 4 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 5 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...

Page 164: ...ut force See Figure 61 8 When working on soft or muddy ground make sure that the machine is not sinking 9 When working close to the excavated edge make sure that the ground the machine is sitting on is solid Keep the travel motors 1 Figure 62 to the rear See Figure 62 10 Do not excavate underneath the machine See Figure 63 FG000134 Figure 60 FG000137 Figure 61 FG000677 1 Figure 62 FG000170 Figure ...

Page 165: ... that there is adequate overhead clearance and that there is adequate ventilation See Figure 65 13 Do not use the bucket as a hammer or ramming device This is dangerous and causes damage to the front attachment See Figure 66 14 Do not dig with the excavator tracks raised This can result in structural and mechanical failures FG000171 Figure 64 FG000172 Figure 65 FG000173 Figure 66 FG000174 Figure 6...

Page 166: ...l be altered Follow these additional operating precautions 17 Do not move dirt or objects by swinging the excavator into them This can result in structural and mechanical failures FG000213 Figure 68 WARNING Do not travel downhill with the front end attachments raised Do not travel across slopes travel straight up or down slope Use extreme caution when swinging the upper frame when positioned on a ...

Page 167: ...ing 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 FG000179 Figure 69 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 FG0...

Page 168: ... operation lever unintentionally it may create a serious accident Before leaving operator s seat set safety lever on LOCK position 120 FG000214 Figure 71 WARNING 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 71 FG000111 Figure 72 HAOB290L Figure 73 FG001091 Unlock lock Figure 74 ...

Page 169: ...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 75 Insert protective material such as thick cloths between track frame and wire rope to prevent the wire rope from being damage IMPORTANT Use shackle hook on track frame to only haul objects that weigh less than 7 metric tons 7 71 U S Tons Never use it to hau...

Page 170: ...ses and tubing to prevent contamination from entering hydraulic system 3 Plug and cap all connectors and fittings on breaker to prevent contamination 4 Check all hydraulic connections for signs of leaks or loose components before starting operation Hydraulic Breaker Operation NOTE Hydraulic pressure and flow settings may need to be changed Refer to the Maintenance Section of this manual for furthe...

Page 171: ...vent damage to cylinders during breaker operation 5 Do not use the breaker if the hydraulic hoses vibrate excessively See Figure 78 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 6 Do not allow the breaker body to go into water if not equipped for underwater operation The...

Page 172: ...he excavator Do not swing the breaker from side to side when operating it See Figure 81 9 Do not curl the breaker tool tip into the arm or boom when traveling or parking the excavator See Figure 82 FG000207 Figure 80 HAOB990L Figure 81 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 FG000216 Figure 82 ...

Page 173: ...on the instrument panel Press the display selector button to show digital pressure reading A separate pressure gauge is not required 3 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 re...

Page 174: ...r is being used These intervals should be followed as opposed to regularly scheduled maintenance Attachment Operation Rate Hydraulic Oil Filter Bucket Work 100 2 000 Hours 250 Hours First Replacement 1 000 Hours After First Replacement Hydraulic Breaker Work 100 500 Hours 100 Hours These service intervals only apply when a genuine DOOSAN oil and filter are used If any other brands are used the gua...

Page 175: ...en Figure 86 will be displayed 2 Use UP or DOWN buttons to adjust flow rate 3 Press SELECT button to return to normal display screen and save the flow rate setting Figure 86 FG001090 Normal Display Flow Control Display C H C E F H 02 05 MO 11 30 E G SPEED 1700 RPM FLOW CONTROL ESC CANCEL APPLY Setting Flow Rate l min 0 48 5 1 57 2 66 3 69 4 78 5 5 90 6 96 5 7 106 5 8 108 9 114 10 114 ...

Page 176: ...ve 1 Select breaker with the selector switch of the right panel 2 Rotate knob 3 Figure 88 120 for stopper 4 Figure 88 be fastened to 5 Figure 88 3 In the condition that 2 Figure 88 is fastened activate the breaker to the direction 1 Figure 88 Adjusting the Stopper 1 Rotate knob 3 Figure 88 in the direction of the arrow then the pedal is activated according to the display caused by 3 Figure 88 knob...

Page 177: ...ositioned into pedal hole A Location for UNLOCKING B Location for LOCKING 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 cont...

Page 178: ...apacity decreases as the distance from the machine swing center line 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 does not exceed the machine LOAD RATING CHART at the radius at which it is to be lifted It is recommended that you feel your way into any lift as a precaution agai...

Page 179: ...onsidered 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 1 Use the shortest lifting radius distance possible 2 Keep the load as close to the ground as conditions will permit 3 Provide tag lines to prevent load from p...

Page 180: ...cted temperatures Refer to the Lubrication Specifications of the engine manual for details 5 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 due to wax crystal formation in the fuel be sure that the fuel used has a cloud point specification below the lowest expected temperature 6 Lubricate ...

Page 181: ...water with a high alkali content which increases scale and rust formation 2 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 gra...

Page 182: ... often as necessary 2 Use care when servicing fuel system to prevent dust and sand from entering the tank 3 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 4 Lubricate and perform services outlined on current lubrication chart on machine a...

Page 183: ...faces in good repair 4 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 at High Altitudes Normally operation of machine at high altitudes will be as outlined in extreme cold Before operating at high altitudes engine fuel ...

Page 184: ...OP000598 Operation 3 48 ...

Page 185: ...eir 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 NOTE Besides the normal hour meter the multifunction gauge can be used to keep track of the hours on...

Page 186: ... requested Keep this number on file incase the machine is stolen 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 l...

Page 187: ...ation 2 Make sure to clean up any fluid spills especially around the engine 3 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 4 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 precautio...

Page 188: ...in types of maintenance may require the machine to be positioned differently Always return machine to this position 1 Park on firm level ground 2 Lower bucket to ground 3 Set safety lever on LOCK position 4 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 FG000111 Figure 6 FG001091 Unlock lock Figure 7 HAOB290L Figure 8 ...

Page 189: ...fore starting maintenance work hang up a tag Do Not Touch When Performing Inspection or Maintenance on cabin door or work lever FG000175 O I Figure 9 WARNING If engine must be run while performing maintenance use extreme care Always have one person in the cabin at all times Never leave the cabin with the engine running Figure 10 FG000401 ...

Page 190: ...SAE 90 and API GL5 SAE 80W 90 and API GL5 Final Drive Case SAE 140 and API GL5 Hydraulic Oil Tank Hydraulic Oil ISO VG 32 ISO VG 46 ISO VG 68 Fuel Tank Diesel Fuel ASTM D975 No 2 ASTM D975 No 1 Grease Fitting Grease Multipurpose Lithium Grease NLGI No 2 Cooling System Coolant Add Antifreeze 50 antifreeze 50 distilled water Installed at factory Engine oil must meet ACEA E5 or API CI 4 Hydraulic oil...

Page 191: ...utomotive Engineers IMPORTANT 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 Fluctuating daily or weekly extremes of temperature or operation in subzero freezing weather may make it impractical to use straight weight lubrica...

Page 192: ...er 22 liters 5 8 U S gal Cooling System 20 liters 5 3 U S gal Fuel Tank 267 liters 70 5 U S gal Hydraulic Oil Tank Level 98 8 liters 26 1 U S gal System 147 8 liters 39 0 U S gal Travel Reduction Device Each 2 1 liters 0 6 U S gal Swing Device 2 liters 0 5 U S gal Symbol Description Symbol Description Lubrication Coolant Gear Oil Swing Device Travel Device Air Cleaner Element Engine Oil Fuel Filte...

Page 193: ...OP000599 4 9 Inspection Maintenance and Adjustment ...

Page 194: ...OP000599 Inspection Maintenance and Adjustment 4 10 Description of Lubrication and Service Chart Figure 11 500h 1000h 2000h 50h 250h 10h 13 12 19 9 20 17 16 10 14 18 15 7 11 1 8 1 1 6 3 4 5 FG009727 ...

Page 195: ...eze 20 L V PG 14 Hydraulic Oil Return Filter Element 1 F 15 Pilot Filter Element 1 F 16 Hydraulic Oil Suction Strainer Strainer 1 C 17 Engine Oil Filter Cartridge 1 F 18 Fuel Filter Cartridge 1 19 Air Cleaner Outer Element 1 C Air Cleaner Inner Element 1 20 Air Conditioner Filter Outer Cartridge 1 C Air Conditioner Filter Inner Cartridge 1 C 21 Dozer Blade Pin Optional Grease 6 F100 W10 V Maintena...

Page 196: ... and Control Console Indicator and Monitor Lights 4 24 Start Engine Check Starting Ability and Observe Exhaust Color at Start up and at Normal Operating Temperature Listen for Any Abnormal Sounds 4 24 Check Operation of All Controls 4 25 50 Hour Weekly Service Perform All Daily Service Checks 4 26 Grease Arm and Front Attachment Pins 4 26 Grease Swing Bearing 4 27 Grease Dozer Blade Pin Optional 4...

Page 197: ...onth service Perform All Daily 50 250 and 500 Hour Service Checks 4 45 Grease Swing Reduction Device 4 45 Replace Hydraulic Oil Return Filter 4 46 Change Pilot Filter 4 47 Change Oil in Travel Reduction Device One on Each Side of Unit 4 48 Change Air Conditioning Outer Filter 4 49 Check Air Conditioner Refrigerant 4 50 Check and Adjust Engine 4 51 2 000 Hour Yearly Service Perform All Daily 50 250...

Page 198: ...0 hours after buying your new machine after which period grease it per 50 hours NOTE In case of performing work underwater grease it per 10 hours irrespective of elapsed period 1 Lower dozer blade to the ground 2 Inject grease at total 6 points by 3 points per dozer cylinder by means of using grease gun Neatly remove old grease that has leaked out after greasing FG000500 Figure 12 WARNING Do not r...

Page 199: ...ark on dipstick some must be drained to return oil to proper level 5 Add oil through engine oil fill cap 2 Figure 14 if the oil level is below the LOW mark Check Level of Hydraulic Oil Tank FG000330 2 1 Figure 14 WARNING Allow the engine to cool before checking the oil level to avoid burns by touching hot engine parts Figure 15 L H FG000616 ARO1760L Figure 16 WARNING The hydraulic oil will be hot ...

Page 200: ...slowly to allow the pressurized air to vent C Remove the upper cover of the hydraulic tank and add oil 6 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 valve Figure 20 at the bottom of the tank into a suitable container using a hose connected to the valve NOTE Dispose of drained fluids according to local r...

Page 201: ...nt Check for Leaks in Hydraulic System 1 Perform a daily walk around inspection to make sure that the hoses piping fittings cylinders and hydraulic motors are not showing any signs of leakage If any is noted determine the source of the leak and repair ...

Page 202: ...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 78 for further information 5 Do not overfill the tank 6 Securely tighten cap after fueling NOTE If breather holes 3 Figure 22 in cap are clogged a vacuum may ...

Page 203: ...left rear side of the machine 3 It is necessary to drain the collected water if the bowl is full of water or sediment 4 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 5 Close drain valve Figure 23 PreLine FG009554 FG000438 1 2 close open Figure 24 ...

Page 204: ...ome must be drained to proper level 4 If the oil does not reach the L mark on the dipstick add oil through fill port 2 Figure 25 5 If the oil level exceeds the H mark on the dipstick open cap 3 Figure 27 of drain valve and connect hose 4 to the valve Drain the excessive oil into a suitable container NOTE Dispose of drained fluids according to local regulations WARNING The gear oil is very hot afte...

Page 205: ...xcavator in dusty area check dust net everyday and clean it if dirty WARNING If using compressed air or water to clean the dust net make sure that proper eye protection is worn 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 wo...

Page 206: ...to this tank Check Level of Window Washer Liquid 1 Open left front access door and check fluid level in windshield washer tank 2 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 Inspect the Bucket Teeth and Side Cutters for Signs of Wear 1 On a daily basis inspect the bucket teeth to make sure that tooth wea...

Page 207: ...o LOCK position and shut down engine 2 Check the engine intake hose and hose bands for damage and tightness 3 If damaged wrinkled or loose replace or retighten or contact your nearest DOOSAN dealer Inspect Seat Belt for Proper Operation Figure 32 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 HAOA050L F...

Page 208: ...the engine Check the Operation of All Exterior Lights Horn and Control Console Indicator and Monitor Lights 1 Turn engine starter switch to the I ON position and observe all of the indicator lights 2 Restore operation of any light bulbs that do not turn ON at this time 3 Sound the horn Repair or replace if required 4 Turn ON and inspect all exterior work lights Replace any monitors burned out bulb...

Page 209: ...ng IMPORTANT Cold weather operation requires that the operator fully warm up the hydraulic oil before beginning machine operation Follow all warm up instructions listed in the Operating Instruction section of this manual Make sure to cycle oil through all of the components including all cylinders both travel motors and the swing motor Cold hydraulic oil in the lines and components needs to be warm...

Page 210: ...d 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 A C B E D FG009560 Figure 35 Reference Number Description A Arm Link Joint Pin 1 Points B Link Joint Pin 2 Points C Arm Bucket Joi...

Page 211: ...ubricate Purge old grease with new Remove all purged grease Grease Dozer Blade Pin Optional NOTE Grease it per 10 hours during initial period of 100 hours after buying your new machine after which period grease it per 50 hours NOTE In case of performing work underwater grease it per 10 hours irrespective of elapsed period 1 Lower dozer blade to the ground 2 Inject grease at total 6 points by 3 poi...

Page 212: ...nspect after first 50 hours of operation and every 250 hours thereafter For details See Check Engine Fan Belt Tension on page 4 32 Change Engine Oil and Filter After First 50 Hours 1 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 37 Inspect the Track Assemblies for Proper Tension and Loose W...

Page 213: ...R MONTHLY SERVICE Perform All Daily and 50 Hour Service Checks 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 52 ...

Page 214: ...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 Figure 41 Reference Number Description A Boom Cylinder Head Pin 2 Points B Boom Foot Pin 2 Points C Boom Cylinder Rod Pin 2 Points D Arm Cylinder Head Pin 1 Point E Boom Arm Joint Pin 2 Points ...

Page 215: ...ts B Boom foot pin 2 points C Boom cylinder rod pin 2 points D Arm cylinder head pin 1 point E Boom arm joint pin 2 points F Arm cylinder rod pin 1 point G Bucket cylinder head pin 1 point Figure 42 A A FG009566 Figure 43 C C D B B FG009567 Figure 44 F E FG006458 Figure 45 G FG006459 ...

Page 216: ...ection 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 2 Before installing new belts make sure all pulley grooves are clean and not worn Replace pulley if damaged or if the grooves are worn 3 All pulley support bearings shafts and brackets must be in working order Figure 46 FAN ALTERNATOR CRANKSHAFT C...

Page 217: ...amaging the belts and pulley grooves NOTE When operating in abrasive conditions check tension every 100 hours Check Oil Level in Travel Reduction Device One on Each Side of Unit 1 Make sure that the machine is on firm level ground 2 Rotate the track until ports 1 thru 3 Figure 48 are in their proper positions as shown 3 Loosen fill plug 3 Figure 48 slightly to allow pressurized air to escape 4 Rem...

Page 218: ... and install the filter housing on the filter head NOTE Tightening torque 27 kg m 265 Nm 195 ft lb 9 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 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 e...

Page 219: ... Change pilot filter after first 250 hours and every 1 000 hours thereafter See page 4 47 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 ...

Page 220: ...able 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 2 If water or other contaminations are found remove the lower access cover so that the gear teeth can be thoroughly cleaned and lubricated 3 Install access covers after lubricating gear teeth WARNING Greasing swing gear and ...

Page 221: ...mall amount of oil around filter gasket Screw filter on head until gasket contacts head turn filter 1 2 turn more 4 Refill the engine with the correct oil through the oil fill port Figure 54 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 5 Start engine Run engine for five minutes at LOW IDLE and ...

Page 222: ...ed more frequently If filter is damaged replace damaged filter with a new one NOTE All right and left call outs are based on the operator being seated in the operator s seat facing the front 1 Open the door in the left of the machine 2 Open the cover by turning the knob 1 Figure 56 in the rear of the cabin WARNING All service and inspection of air conditioning system should be performed with the s...

Page 223: ...dle which is inside of the left rear part of the cabin 2 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 Figure 57 FG000342 Figure 58 FG000422 WARNING All service and inspection of air conditioning system should be performed with the starter switch in the O OFF position WARNING If u...

Page 224: ...ds to remove all dirt and debris NOTE Clean dust net and install it after cleaning radiator oil cooler intercooler and fuel cooler 4 Clean air conditioner condenser core with compressed air steam or water Figure 59 FG009572 WARNING If compressed air steam or water hit your body directly there is danger of injury Always wear protective glasses mask and safety shoes during the cleaning precess Make ...

Page 225: ... after cleaning 5 times or every 2 000 hours 1 year of service 2 Remove and clean rubber evacuator valve 1 Figure 63 from bottom of air cleaner housing cover 2 Inspect seal lips for wear or damage Replace valve if necessary NOTE Install evacuator valve with lips parallel to the cover 3 Remove the access cover 2 Figure 64 by loosening the latches 3 4 Remove the outer filter 4 Figure 64 from the hou...

Page 226: ...compressed air 8 Properly install the air filter and cover 9 After filter service be sure to install cover with arrows pointing UP NOTE If after cleaning the outer filter the air cleaner clogged indicator remains ON replace the outer and inner filters Do not clean inner filter Change of Fuel Prefilter 1 Open the left rear side door to access fuel prefilter 2 Position a small container under prefil...

Page 227: ...nside engine compartment 2 Position a small container under fuel filter 3 Unscrew fuel filter from head assembly Discard fuel filter NOTE Dispose of drained fluids according to local regulations 4 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...

Page 228: ...el or if the fuel filter has been replaced air may need to be bleed using the following procedure 1 Shut down engine 2 Loosen plug 1 Figure 72 on the fuel prefilter head 3 Pump the hand operated primer pump 2 Figure 72 on the fuel prefilter Pump primer until fuel is present at plug hole in fuel prefilter head 4 Tighten plug 1 Figure 72 in fuel prefilter head 5 Continue to pump primer pump until a ...

Page 229: ... Position the machine on firm level ground Lower the front attachment to the ground and shut down engine 2 Remove air vent plug 1 Figure 73 from swing reduction device 3 Press grease fitting and inject grease with the grease gun on the marked point 2 Figure 74 4 Install air vent plug 1 Figure 73 in swing reduction device Figure 73 1 FG006316 Figure 74 2 FG009576 ...

Page 230: ...ons 5 Install new filter and a new O ring Install bypass strainer valve and spring Install service cover plate 6 Tighten the breather cap 1 Figure 76 7 Run engine for ten minutes at low idle to purge air from circuit 8 Check level in hydraulic oil tank See page 4 15 Add oil if necessary Figure 75 C H C E F H E G SPEED 1700 RPM FG000760 02 05 MO 11 30 1 3 2 FG009577 Figure 76 WARNING The hydraulic ...

Page 231: ...Unscrew canister 5 Figure 80 and remove O ring 3 and filter cartridge 4 NOTE The canister will be filled with oil Use caution when removing this assembly 5 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 80 NOTE Used filter should always be disposed of according to local regulations 6 Afte...

Page 232: ...he travel reduction gear oil NOTE Dispose of drained fluids according to local regulations 4 Install drain plug 2 Figure 81 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 5 Repeat this procedure on the other travel reduction device Figure 81 2 3 1 FG00956...

Page 233: ...t the cleaning and replacement should be performed more frequently If filter is damaged replace damaged filter with a new one NOTE All right and left call outs are based on the operator being seated in the operator s seat facing the front 1 Open the door in the left of the machine 2 Open the cover by unscrewing the knob 1 Figure 83 in the rear of the cabin WARNING All service and inspection of air...

Page 234: ...control switch in maximum cooling position 4 Press the Internal Air Circulation switch 5 Compare the flow of bubbles in the sight glass of receiver dryer with the drawings in the following table Figure 84 FG000342 Figure 85 FG009579 WARNING Mixing of tobacco smoke and freon is deadly Do not smoke while servicing or recharging air conditioning system CAUTION Overfilling refrigerant may cause danger...

Page 235: ... and adjusting the following items Engine Compression Pressure Injection Pressure Injection Timing Amount of Refrigerant Appearance of the Sight Glass Solutions Normal Almost clear Any bubbles disappear High No bubbles are seen Charge or withdraw the system with the correct amount of HFC 134a refrigerant Low A flow of bubbles is visible ...

Page 236: ...er 1 Set a container under excavator 2 Remove cap 3 Figure 87 and install hose 4 to drain the swing reduction device oil NOTE Dispose of drained fluids according to local regulations 3 After draining oil remove hose and install cap 4 Remove breather fill cap 2 Figure 86 and add oil to H mark on dipstick 1 2 1 FG009555 Figure 86 WARNING The gear oil is very hot after the machine has been operating ...

Page 237: ...ve if necessary Install evacuator valve with lips parallel to the cover 3 Remove outer filter 4 Figure 90 from the air cleaner housing 4 Clean the air cleaner cover and the inside of the air cleaner housing 5 Remove inner filter 5 Figure 91 6 Clean out inside of air cleaner housing Do not use compressed air to blow out housing 7 Install new inner filter Do not clean and reuse inner element 8 Insta...

Page 238: ...ain from heater core Figure 92 ARO1760L WARNING Allow the engine to cool before releasing the radiator cap Make sure to loosen the cap slowly to release any remaining pressure Radiator cleaning is performed while the engine is running Take extreme caution when working on or near a running engine Make sure to lock out and tag the controls notifying personnel that service work is being performed Do ...

Page 239: ... 77 12 Run engine without radiator cap installed so that all air will be purged from system Fill radiator to fill neck 13 Drain and fill radiator coolant recovery tank Hydraulic Oil Exchange and Suction Strainer Cleaning Figure 95 FG000322 1 Figure 96 ARO1760L WARNING The hydraulic oil will be hot after normal machine operation Allow the system to cool before attempting to service any of the hydra...

Page 240: ...reather cap 1 Figure 100 5 Drain hydraulic oil from tank into a container capable of holding 147 8 liters 39 U S gal After draining tank install drain plug NOTE Used filter and used oil should always be disposed of according to local regulations 6 Carefully remove bolts and cover 2 Figure 100 from top of hydraulic oil tank There is a spring 3 under the cover that will force the cover up 7 Remove s...

Page 241: ... page 4 15 Check Alternator and Starter These checks need to be completed by an authorized DOOSAN dealer Check All Rubber Antivibration Shock Mounts Perform and Record the Results of the Cycle Time Tests Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage Check Adjust Valve Clearance Check Head Bolt Torques 1 2 3 4 5 6 ARO1720L Figure 100 IMPORTANT When the hydraulic br...

Page 242: ...ce 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 2 years or 4 000 hours 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 Conditio...

Page 243: ... 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 rela...

Page 244: ... Check the hose for cracking and damage 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 40 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 Tens...

Page 245: ...ank 16 4 24 27 264 195 6 Tightening bolt for pump 10 12 17 6 5 64 47 7 Tightening bolt for control valve 16 4 24 27 264 195 8 Tightening bolt for swing reduction device 16 9 24 27 264 195 9 Tightening bolt for swing motor 12 10 10 S 11 108 80 10 Tightening bolt for battery 10 2 17 6 5 64 47 11 Joint bolt with cabin mounting rubber and frame 10 16 17 6 5 64 47 Joint bolt with cabin mounting rubber ...

Page 246: ...que 27 kg m 264 Nm 195 ft lb 2 Fan side Tool 17 mm Torque 6 5 kg m 64 Nm 47 ft lb 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 2 Fan side Tool 30 mm Torque 46 kg m 451 Nm 333 ft lb FG009582 Figure 101 FG006423 Figure 102 FG009583 Figure 103 FG006424 Figure 104 ...

Page 247: ... ft lb 4 Tightening bolt for hydraulic oil tank Tool 24 mm Torque 27 kg m 264 Nm 195 ft lb 5 Tightening bolt for fuel tank Tool 24 mm Torque 27 kg m 264 Nm 195 ft lb 6 Tightening bolt for pump Tool 17 mm Torque 6 5 kg m 64 Nm 47 ft lb FG009584 Figure 105 FG009585 Figure 106 FG009586 Figure 107 FG009587 Figure 108 ...

Page 248: ...5 ft lb 8 Tightening bolt for swing reduction device Tool 24 mm Torque 27 kg m 264 Nm 195 ft lb 9 Tightening bolt for swing motor Tool 10 mm Torque 11 kg m 108 Nm 80 ft lb 10 Tightening bolt for battery Tool 17 mm Torque 6 5 kg m 64 Nm 47 ft lb FG009588 Figure 109 FG009589 Figure 110 FG009590 Figure 111 FG009591 Figure 112 ...

Page 249: ...nt bolt with cabin mounting rubber and cabin Tool 24 mm Torque 21 kg m 205 Nm 152 ft lb 12 Joint bolt with swing bearing and upper frame Tool 30 mm Torque 55 kg m 539 Nm 398 ft lb Joint bolt with swing bearing and bottom frame Tool 30 mm Torque 55 kg m 539 Nm 398 ft lb FG000454 Figure 113 FG000455 Figure 114 FG000456 Figure 115 FG000457 Figure 116 ...

Page 250: ...m 217 ft lb Tightening bolt for sprocket Tool 24 mm Torque 30 kg m 294 Nm 217 ft lb 14 Tightening bolt for upper roller Tool 30 mm Torque 55 kg m 539 Nm 398 ft lb 15 Tightening bolt for bottom roller Tool 24 mm Torque 27 kg m 264 Nm 195 ft lb FG009592 Figure 117 FG009593 Figure 118 FG000460 Figure 119 FG000461 Figure 120 ...

Page 251: ...ng bolt for track guard Tool 24 mm Torque 27 kg m 264 Nm 195 ft lb 17 Bolt for track shoes Tool 24 mm Torque 39 kg m 382 Nm 282 ft lb 18 Fixing bolt for front pin Tool 24 mm Torque 27 kg m 264 Nm 195 ft lb FG000462 Figure 121 FG000463 Figure 122 FG009911 Figure 123 ...

Page 252: ...enance and Adjustment 4 68 19 Fixing breaker filter Optional Tool 30 mm Torque 27 kg m 264 Nm 195 ft lb 20 Grease valve for track adjuster Tool 27 mm Torque 14 kg m 137 Nm 101 ft lb FG009569 Figure 124 1 3 2 FG000163 Figure 125 ...

Page 253: ...h to drive locking pin 2 and lock washer 3 out of tooth adapter 4 3 Once worn tooth has been removed use a putty knife to scrape adapter as clean as possible 4 Slide new tooth into position and insert lock washer 5 Insert locking pin into tooth and with a hammer drive pin in until lock washer seats in locking groove WARNING Due to the possibility of flying metal objects always wear safety helmet p...

Page 254: ...t link 4 out of way 3 Remove old O ring and temporarily install new O ring 1 Figure 130 onto bucket boss 2 Make sure that O ring groove on both bucket link 4 and boss have been cleaned 4 Realign arm or link with bucket pin hole and insert bucket pin 3 Figure 129 WARNING Due to possibility of flying metal objects always wear safety helmet protective gloves and eye protection when changing pins FG00...

Page 255: ...OP000599 4 71 Inspection Maintenance and Adjustment 5 Roll new O ring 1 Figure 131 into O ring groove ARO1392L 1 Figure 131 ...

Page 256: ...em 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 bat...

Page 257: ...id on the battery surface terminals and cable connectors Petroleum jelly or grease can be applied to the connectors to help prevent corrosion Battery Replacement When the charging indicator indicates transparency state replace the battery The batteries should always be replaced in pairs Using an old battery with a new one will shorten the life span of the new battery Fuses 1 The fuses in the fuse ...

Page 258: ...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 fuse separates check the circuit and repair the circuit CAUTION Before replacing a fuse be sure to turn starter switch to O OFF position FG000110 Figure 135 CAUTION Always replace fuses with the same type and c...

Page 259: ...V 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 8 Starter Switch Hour Meter 10A 8 Room Light 10A 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 12 Seat Heater Optional 15A 12 Instrument Panel Pressure Senso...

Page 260: ...t 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 Heavy duty diesel engines require a balanced mixture of water and antifreeze Drain and replace the mixture every year or 2 000 hours of op...

Page 261: ...he 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 NOTE Do not mix ethylene glycol...

Page 262: ...ly 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 ...

Page 263: ...A thermal limiter built into the motor will automatically shut off power if motor is overheating to protect it from being damaged 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 FUEL FUEL T...

Page 264: ...on front side to I ON position NOTE Transfer pump rate of flow is approximately 35 liters minute 9 24 U S gpm Use extra care not to overfill fuel tank so that fuel does not over flow 4 Once fuel transfer is completed immediately turn switch to O OFF position to stop pump 5 Lift inlet hose 5 Figure 137 from fueling source and turn switch to I ON position for two three seconds to drain remaining fue...

Page 265: ... 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 eng...

Page 266: ...material in the track assembly Clean off the tracks before checking clearance 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...

Page 267: ...e 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 hole in valve 3 Figure 142 by loosening valve slowly 3 Figure 142 NOTE After track tension is adjusted by loosening valve be sure to tighten valve 3 Figure 142 with 14 ...

Page 268: ...will pressurize the hydraulic oil tank and system 5 Slowly loosen vent plug Figure 143 several turns until hydraulic oil flows out of plug This shows that air has been released 6 Tighten the plug Figure 143 Hydraulic Cylinders 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 R...

Page 269: ...ect drain hose 4 Start engine and set engine speed control dial to LOW IDLE Run the engine for one minute and slowly drive 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 ...

Page 270: ...t oil to all of the control linkages and control cylinders control valve spools etc Battery Remove the battery from the excavator or remove the battery leads from the battery to fully charge and store Cooling System Inspect the coolant recovery tank to make sure that the antifreeze level in the system is at the correct level Every 90 days use a hydrometer to measure the protection level of the coo...

Page 271: ...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 ...

Page 272: ...OP000599 Inspection Maintenance and Adjustment 4 88 ...

Page 273: ...UNLOADING Warning for Counterweight and Front Attachment Removal FG000371 Figure 1 DANGER DOOSAN warns any user that the 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 the counterweight or front attach...

Page 274: ...ting and travel at the slowest speed possible Make sure that the ramp being used can handle the weight of the machine If required add blocking under the ramp for additional support Make sure that the ramp surface is free of grease or mud that could cause the machine to slip or slide Make sure that the trailer is parked on firm level ground before attempting to load unload the excavator If it is re...

Page 275: ...he front and travel forward to load it 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 that the counterweight end of the excavator is positioned on the ramp first See Figure 6 FG000023 O I II Figure 3 1 5 POWE...

Page 276: ...trailer before transporting Place blocking 1 Figure 10 in front of and behind each track Use chains or cable tie downs 2 as required by local transportation laws 14 Refer to the Dimensions for Transportation table and drawing for overall machine height and width measurements Make sure to position the excavator as shown If not transported in this position the height measurements may be different FG...

Page 277: ...ing 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 are properly secured to them and that the angle of the cables is factored into the lift strength Figure 11 WARNING Improper lifting can allow load to shift and cause injury or damage ...

Page 278: ...OP000600 Transportation 5 6 ...

Page 279: ...Cause Remedy Battery will not hold a charge Low battery power Clean and retighten 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 controllable Speed control dial failed...

Page 280: ...rter 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 does not start Fuel gelled in cold weather Replace fuel Fuel filters plugged Replace filters Water or dirt in fuel system Clean system and add new fuel Air in fuel system Purge air from system Engine sto...

Page 281: ...ntact 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 Problem Cause Remedy Problem Cause Re...

Page 282: ...ir 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 Problem Cause Remedy Problem Cause Remedy No swinging m...

Page 283: ...rking 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 ...

Page 284: ...OP000013 Troubleshooting 6 6 ...

Page 285: ...scharging pressure 330 kg cm2 4 700 psi Maximum discharge quantity 2 x 114 liters min 2 x 30 1 U S gpm Hydraulic oil capacity Tank Level 98 8 liters 26 1 U S gal System 147 8 liters 39 0 U S gal Performance Digging capability Bucket 10 5 metric tons 11 6 tons Arm 6 2 metric tons 6 8 tons Swing speed 10 7 rpm Travel speed High speed 4 7 km h 2 9 MPH Low speed 3 km h 1 9 MPH Traction force High spee...

Page 286: ... m 6 11 Arm 2 5 m 8 2 Arm 3 0 m 9 10 Arm A 7 690 mm 25 3 7 680 mm 25 2 7 640 mm 25 0 B 2 200 mm 7 2 C 5 490 mm 18 0 5 480 mm 17 11 5 440 mm 17 10 D 3 034 mm 9 11 E 3 755 mm 12 4 F 894 mm 2 11 G 2 570 mm 8 5 2 710 mm 8 10 3 090 mm 10 1 H 2 540 mm 8 4 I 1 270 mm 4 2 J 1 270 mm 4 2 K 1 990 mm 6 6 L 2 590 mm 8 6 M 600 mm 2 0 N 410 mm 1 4 O 2 773 mm 9 1 ...

Page 287: ...4 Two Piece BOOM 2 1 m 6 11 Arm 2 5 m 8 2 Arm A 8 060 mm 26 5 8 015 mm 26 4 B 2 200 mm 7 2 C 5 860 mm 19 3 5 815 mm 19 1 D 3 180 mm 10 4 E 3 968 mm 13 0 F 1 035 mm 3 4 G 2 655 mm 8 9 2 770 mm 9 1 H 2 540 mm 8 4 I 1 270 mm 4 2 J 1 270 mm 4 2 K 2 200 mm 7 2 L 2 800 mm 9 2 M 600 mm 2 0 N 455 mm 1 5 O 2 925 mm 9 6 ...

Page 288: ...iece BOOM 2 1 m 6 11 Arm 2 5 m 8 2 Arm 3 0 m 9 10 Arm A Max Digging Reach 7 845 mm 25 9 8 300 mm 27 3 8 680 mm 28 6 B Max Digging Depth 5 250 mm 17 3 5 645 mm 18 6 6 150 mm 20 2 C Max Digging Height 8 195 mm 26 11 8 675 mm 28 5 8 745 mm 28 8 D Max Loading Height 5 875 mm 19 3 6 300 mm 20 8 6 415 mm 21 0 E Min Swing Radius 2 345 mm 7 8 2 375 mm 7 9 2 585 mm 8 6 ...

Page 289: ...A E Figure 3 DIM 4 98 m 16 4 Two Piece BOOM 2 1 m 6 11 Arm 2 5 m 8 2 Arm A Max Digging Reach 8 380 mm 27 6 8 805 mm 28 11 B Max Digging Depth 5 440 mm 17 10 5 850 mm 19 2 C Max Digging Height 8 820 mm 28 11 9 235 mm 30 4 D Max Loading Height 6 420 mm 21 1 6 810 mm 22 4 E Min Swing Radius 2 925 mm 9 7 2 935 mm 9 8 ...

Page 290: ...SS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry size 449 kg m3 756 lb yd3 Coal bituminous slack piled 801 kg m3 1 350 lb yd3 Coal bituminous r of m piled 881 kg m3 1 485 lb yd3 Coal anthracite 897 kg m3 1 512 lb yd3 Clay DRY in broken lumps 1 009 kg m3 1 701 lb yd3 Clay DAMP natural bed 1 746 kg m3 2...

Page 291: ...95 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1 282 kg m3 2 160 lb yd3 Salt 929 kg m3 1 566 lb yd3 Snow light density 529 kg m3 891 lb yd3 Sand DRY loose 1 522 kg m3 2 565 lb yd3 Sand WET packed 1 922 kg m3 3 240 lb yd3 Shale broken 1 362 kg m3 2 295 lb yd3 Sulphur broken 529 kg m3 1 620 lb yd3 MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3...

Page 292: ...OP000601 Specification 7 8 ...

Page 293: ...e Cutters 4 22 Tooth 4 69 C Cabin Light 2 59 Cabin Storage Compartments 2 69 Cabin Work Light Switch 2 15 Ceiling Cover 2 65 Charge Warning Light 2 28 Check and Confirmation After Stopping Engine 3 12 Cigarette Lighter 2 18 Circuit Breaker 2 59 Clock 2 27 2 41 Cold Weather Hydraulic System Warm up 3 10 Cold Weather Starting 3 6 Communication Error Warning 2 32 Indicator 2 31 Component Locations 2 ...

Page 294: ... and Air Conditioner 2 51 Additional Operating Instruction 2 56 Control Panel 2 16 2 52 Filter 4 38 4 49 Location of Controls and Vents 2 51 Memory Function of Used Mode 2 56 Refrigerant 4 50 System 4 60 Horn Button 2 20 Hose Clamps 4 35 Hour Meter 2 28 Hydraulic System 6 3 Flow Control 2 47 Front Hydraulic Pump Pressure 2 33 General Venting 4 85 Hydraulic Breaker 3 34 Hydraulic Hoses and Tubing 3...

Page 295: ...r Cleaner Element 4 53 Outer Element of Air Cleaner 4 41 Overall Dimensions 7 2 Overload Alarm Selection 2 50 Overload Warning Switch Optional 2 19 P Panels Air Conditioner Control Panel 2 16 Audio Control 2 12 Heater and Air Conditioner 2 51 Heater and Air Conditioner Control Panel 2 52 Instrument 2 21 Instrument Panel 2 24 Wiper Switch 2 16 Parking Excavator 3 32 Password Activated 2 25 Set Pass...

Page 296: ...er 2 18 Constant Speed Button 2 17 Display Selector Button 2 39 Down Arrow Button 2 39 Engine Emergency Stop 2 12 Engine Speed Control 3 20 Engine Speed Control Dial 2 10 ESC Button 2 40 Flow Control Button 2 37 Fuel Heater 2 19 Headlight Switch 2 14 Horn Button 2 20 Intermittent Speed Button 2 17 Overload Warning Optional 2 19 Pilot Cutoff Switch 2 59 Power Mode Selector Button 2 36 Power Socket ...

Page 297: ...ton 2 17 Water Separator 4 19 Weight of Workload Materials 7 6 Window Washer Liquid 4 22 Windows Door Window Holder 2 71 Front 2 66 Front Bottom 2 67 Front Upper 2 66 Opening 2 66 Sun Visor 2 70 Wiper Switch Lower 2 16 Wiper Switch Panel 2 16 Work Levers Joysticks ISO Style 3 23 Work Light Indicator Light 2 30 Work Mode 3 21 Working Range 7 4 ...

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