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Copyright

Doosan

2006

K1028289E Operation and Maintenance Manual

DOOSAN

reserves the right to improve its products continuously, delivering the best possible product to

the marketplace. These improvements can be implemented at any time with no obligation to change
materials previously sold. It is recommended that consumers periodically contact their distributors for most
recent documentation on purchased equipment.

This documentation may include attachments and optional equipment 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
equipment, and may vary from the actual item.

Operation and Maintenance Manual

K1028289E

Serial Number 5001 and Up

December 2006

DX27Z

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Summary of Contents for DX27Z

Page 1: ... consumers periodically contact their distributors for most recent documentation on purchased equipment This documentation may include attachments and optional equipment 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 equipment and may va...

Page 2: ......

Page 3: ...3 Machine Operation 1 27 Maintenance 1 35 Battery 1 42 Towing 1 44 Shipping and Transportation 1 45 Excavator Rated Lift Capacity Tables 1 46 Operating Controls 2 1 Component Locations 2 2 Operator s Area 2 4 Operational Controls and Panels 2 6 instrument Panel 2 13 Stereo Optional 2 18 Fuse boxes 2 19 Miscellaneous Electrical Devices 2 20 Heating System Optional 2 21 Seat Adjustment 2 23 Seat Bel...

Page 4: ...7 Operation Under Unusual Conditions 3 39 Inspection Maintenance and Adjustment 4 1 Preventive Maintenance 4 1 Preliminary Work Machine Setup for Maintenance 4 3 Table of Recommended Lubricants 4 5 Fluid Capacities 4 7 Lubrication and Service Chart 4 7 Maintenance Intervals 4 10 10 Hour Daily Service 4 12 50 Hour Weekly Service 4 20 250 Hour Monthly Service 4 23 500 Hour 3 Month Service 4 29 1 000...

Page 5: ...Hydraulic System 4 58 Transportation 5 1 Loading and Unloading 5 1 Lifting With Sling 5 4 Troubleshooting 6 1 Control Valve 6 1 Relief Valve 6 2 Center Joint 6 2 Control Lever 6 3 Attachments 6 3 Hydraulic Motor 6 4 Hydraulic Cylinder 6 4 Hydraulic Pump 6 5 Swing System 6 5 Travel 6 6 Specification 7 1 Standard Specification 7 1 Overall Dimensions 7 2 Working Range 7 4 Approximate Weight of Worklo...

Page 6: ...K1028289E Table of Contents IV ...

Page 7: ...tions on page 1 13 4 General Hazard Information on page 1 13 5 Before Starting Engine on page 1 23 6 Machine Operation on page 1 27 7 Maintenance on page 1 35 8 Battery on page 1 42 9 Towing on page 1 44 10 Shipping and Transportation on page 1 45 11 Excavator Rated Lift Capacity Tables on page 1 46 DANGER Unsafe use of the excavator could lead to serious injury or death Operating procedures maint...

Page 8: ...ven 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 ...

Page 9: ...njury or accidents Always observe safety precautions and follow recommended procedures CAUTION This word is used on safety messages and safety labels and indicates potential threat 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 i...

Page 10: ...efore 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 any procedures contact a DOOSAN distributor ...

Page 11: ...ds 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 damaged o...

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: ...OP000522 1 7 Safety 3 Warnings When Opening a Front Window 2190 3388 190 00093 4 Warnings for a High pressure Cylinder 190 00122 FG000665 2190 3388 190 00093 190 00122 ARO1110L ...

Page 14: ...OP000522 Safety 1 8 5 Warnings When Adjusting Track Tension 2190 3386A 190 00521 6 Warnings for Leaving Operator s Seat 190 00693 190 00094 190 00521 2190 3386A ARO1120L ARO1140L 190 00094 190 00693 ...

Page 15: ...OP000522 1 9 Safety 7 Warnings for Batteries Maintenance 2190 2533A 190 00100 8 Warnings for High Temperature Hydraulic Oil 190 00691 190 00097 ARO1150L 190 00100 2190 2533A ARO1160L 190 00691 190 00097 ...

Page 16: ...OP000522 Safety 1 10 9 Warnings for Hot Coolant 190 00692 190 00097 10 Warnings for Rotating Parts 190 00694 190 00095 190 00557 ARO1170L 190 00097 ARO1190L 190 00095 190 00557 ...

Page 17: ...ag Used When Inspection and Maintenance 190 00695 190 00098 12 Keep Out of the Swing Area 2190 3380A 190 00163 190 00098 ARO1200L WARNING DO NOT OPERATE when performing inspection or maintenance 190 00695 FG008064 2190 3380A 190 00163 ...

Page 18: ...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 19: ...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 judgment 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 tha...

Page 20: ... 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 locked the machine may sudden...

Page 21: ... and cabin conditions as described in ISO 6396 NOTE The guaranteed sound power level emitted by the machinery for this machine is 93 dB A Measurement is obtained on a dynamic machine with the procedures as described in 2000 14 EC Vibration Level Information Hands Arms The weighted root mean square acceleration to which the hands arms are subjected is less than 2 5 m s2 Whole body The weighted root...

Page 22: ...es steering linkages etc 4 Steer brake accelerate shift gears move the attachments and load the attachments smoothly 5 Adjust the machine speed and travel path to reduce the vibration level Slow down if it is necessary when traveling through rough terrain When driving machine avoid obstacles and excessive rough terrain 6 Keep the machine on terrain where working and traveling conditions are good R...

Page 23: ...d cause you to fall Use the points marked by arrows in the diagram when getting on or off the machine Fuel Oil and Hydraulic Fluid Fire Hazards Fuel oil and antifreeze will catch fire if it is brought close to a flame Fuel is particularly flammable and can be hazardous Always strictly observe the following Add fuel oil antifreeze and hydraulic fluid to the machine only in a well ventilated area Th...

Page 24: ...hot oil from spurting out shut down engine wait for the oil to cool then loosen the cap slowly to relieve the pressure Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your health if it is inhaled Materials containing asbestos fiber can be present on work site Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage To prevent lung damage from a...

Page 25: ...e mounted in the cabin Check and service the fire extinguisher at regular intervals and make sure that all work site crew members are adequately trained in its use Provide a first aid kit in the storage compartment and keep another at the work site Check the kit periodically and make any additions if necessary Know what to do in case of injury from fire Keep emergency numbers for doctor ambulance ...

Page 26: ...ld strike the operator s cabin Make sure that all other work site crew members are kept well away from the excavator and safe from possible hazards For breaker operation install a front guard and apply a laminated coating sheet to the front glass Contact your DOOSAN distributor for recommendations When carrying out demolition or cutting operation install a front guard and top guard and apply a lam...

Page 27: ...ot drill or make any holes in the accumulator or expose it to any flames fire or heat source Do not weld on the accumulator or try attaching anything to it When carrying out disassembly or maintenance of the accumulator or when disposing of the accumulator the charged gas must be properly released Contact your DOOSAN distributor Wear safety goggles and protective gloves when working on an accumula...

Page 28: ...rator seat in the upper left 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 point to break the glass FG006340 Figure 13 WARNING Protect your eyes when breaking the glass ...

Page 29: ...d take other steps to prevent people from coming close to or entering the work site If people come close to a moving machine they may be hit or caught by the machine and this may lead to serious personal injury or death Waterlines gas lines phone lines and high voltage electrical lines may be buried under the work site Contact each utility and identify their locations Be careful not to damage or c...

Page 30: ...if working in areas where there is danger of falling rocks Checks Before Starting Engine Every day before starting the engine for the first time carry out the following checks If these checks are not carried out properly there is danger of serious injury Remove all wood chips leaves grass paper and other flammable materials accumulated in the engine compartment and around the battery They could ca...

Page 31: ...if there is any indication that maintenance or service work is in progress or if a warning tag is attached to controls in the cabin A machine that has not been used recently or is being operated in extremely cold temperatures could require a warm up or maintenance service before start up Check gauges and monitor displays for normal operation before starting the engine Listen for unusual noises and...

Page 32: ...If the machine is used without repairing the problems it may lead to unexpected injury or failure Clear all personnel from directly around machine and from the area Clear all obstacles from the machine s path Beware of hazards Be sure that all windows are clean Secure the doors and the windows in the open position or in the shut position Adjust the rearview mirrors for best visibility close to the...

Page 33: ...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 34: ...cle 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 the ...

Page 35: ... 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 36: ...ined by the structure of the machine When working at the edge of an excavation or on a road shoulder the machine could tip over possibly resulting in serious injury or death Investigate the configuration and ground conditions of the work site beforehand to prevent the machine from falling and to prevent the ground stockpiles or banks from collapsing Precautions for Operation Be careful not to mist...

Page 37: ...es not have to make physical contact with power lines for current to be transmitted Use a spotter and hand signals to stay away from power lines not clearly visible to the operator Use these minimum distances as a guideline only Depending upon the voltage in the line and atmospheric conditions strong current shocks can occur with the boom or bucket as far away as 4 6 m 13 20 ft from the power line...

Page 38: ...ecessary When the temperature rises frozen road surfaces become soft and machine travel becomes unstable In cold weather do not touch metal surfaces with your bare hands If you touch a metal surface in extremely cold weather your skin may freeze to the metal surface Operations on Slopes When working on slopes there is danger that the machine may lose its balance and turn over when swinging or when...

Page 39: ...necessary signs to ensure that passing traffic can see the machine clearly Park the machine so the machine flags and fences do not obstruct traffic After all attachments such as the bucket and blade have 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 LOCKED position This will disable all pilot c...

Page 40: ...er Let Anyone Ride on Attachment Never let anyone ride on any work attachment such as the bucket crusher grapple or clamshell grab bucket There is a danger of the person falling and suffering serious injury ARO1310L Figure 28 ...

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: ...attery electrolyte or window washing fluid always use lighting with antiexplosion specifications Danger of an explosion is elevated when proper lighting equipment is not used If work is carried out in dark places without using lighting it may lead to injury so always use proper lighting Even if the place is dark never use a lighter or flame instead of lighting There is danger of fire There is also...

Page 43: ...battery charging areas or in areas the contain flammable material Clean all electrical connections and tighten all electrical connections Check the electrical wires daily for wires that are loose of frayed Tighten all lose electrical wires before you operate the machine Repair all frayed electrical wires before you operate the machine Remove all flammable materials before they accumulate on the ma...

Page 44: ...ake sure that the hydraulic tank filter plug is cool before you remove it with your bare hand Remove the hydraulic tank filter plug slowly to relieve pressure Relieve all pressure in the hydraulic oil system in the fuel system or in the cooling system before you disconnect any lines fittings or related items Batteries give off flammable fumes that can explode Do not smoke while you are checking th...

Page 45: ... never use any area except the area equipped with nonslip pads Track Tension Adjustments Require Caution Never turn out the track tension grease fitting nut To release pressure from the crawler frame track tension assembly you should NEVER 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 tra...

Page 46: ...but pressurized oil has enough force to pierce the skin and cause serious injury Always use a piece of wood or cardboard to check for suspected hydraulic leaks Never use your hands or 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 corre...

Page 47: ... 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 48: ...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 49: ...ches on the battery charger or boost starting equipment When boost starting from another machine or vehicle do not allow the two machines to touch Wear safety glasses or goggles while required battery connections are made Connect positive cable first when installing cables and disconnect the negative cable first when removing them The final cable connection at the metal frame of the machine being ...

Page 50: ...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 51: ...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 52: ...o rotate If the surface area of the load is large enough wind gusts can create side loads Keep the bucket hook point directly over the load Tag lines on opposite sides of the load can help maintain greater stability against side loads and wind gusts Figure 44 WARNING Let everybody be away from the boom cylinder While lifting operation boom arm bucket hoses might burst and then high pressure oil wi...

Page 53: ...ift 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 lift height in the reference drawing Figure 45 The weight of slings and any auxi...

Page 54: ... 0 74 0 92 0 74 0 74 0 74 0 67 0 68 0 66 0 65 0 64 0 64 0 64 0 57 0 56 0 54 0 53 0 53 0 52 0 52 0 51 0 52 0 51 0 51 0 50 0 49 0 48 0 48 0 49 0 43 0 43 0 43 0 42 0 41 0 40 0 40 0 40 0 40 0 40 0 39 0 39 0 39 0 38 0 33 0 33 0 32 0 32 0 32 0 50 0 42 0 37 0 35 0 34 0 34 0 36 0 40 0 48 0 67 0 42 0 35 0 29 0 28 0 28 0 30 0 33 0 39 0 31 0 55 3 03 3 39 3 63 3 76 3 80 3 76 3 63 3 40 3 04 2 46 2 37 2 38 2 41...

Page 55: ...1 67 0 74 0 74 0 74 0 67 0 85 1 04 1 17 1 22 1 19 1 07 0 57 0 56 0 54 0 53 0 53 0 52 0 52 0 58 0 57 0 62 0 71 0 81 0 89 0 92 0 90 0 77 0 43 0 43 0 43 0 42 0 41 0 40 0 40 0 40 0 40 0 60 0 64 0 69 0 73 0 74 0 33 0 33 0 32 0 32 0 32 0 59 0 59 0 60 0 62 0 64 0 66 0 69 0 72 0 75 0 76 0 42 0 35 0 29 0 28 0 28 0 30 0 33 0 39 0 31 0 55 3 03 3 39 3 63 3 76 3 80 3 76 3 63 3 40 3 04 2 46 2 37 4 08 3 31 1 87 ...

Page 56: ...0 70 0 58 0 61 0 60 0 58 0 57 0 57 0 57 0 49 0 49 0 55 0 55 0 54 0 53 0 53 0 53 0 53 0 47 0 47 0 47 0 46 0 45 0 44 0 44 0 43 0 44 0 44 0 44 0 43 0 43 0 42 0 36 0 36 0 36 0 35 0 35 0 49 0 41 0 37 0 35 0 35 0 35 0 36 0 40 0 46 0 60 0 41 0 34 0 29 0 29 0 29 0 30 0 33 0 38 0 31 0 50 3 27 3 61 3 82 3 95 3 99 3 95 3 83 3 61 3 28 2 78 2 58 2 58 2 61 2 04 2 05 2 07 1 40 1 68 1 63 1 60 1 59 1 60 1 40 1 38 ...

Page 57: ...12 0 58 0 61 0 60 0 58 0 57 0 57 0 57 0 49 0 49 0 55 0 65 0 76 0 85 0 90 0 91 0 84 0 47 0 47 0 47 0 46 0 45 0 44 0 44 0 43 0 44 0 53 0 54 0 59 0 65 0 70 0 36 0 36 0 36 0 35 0 35 0 53 0 54 0 55 0 57 0 59 0 61 0 64 0 67 0 70 0 73 0 41 0 34 0 29 0 29 0 29 0 30 0 33 0 38 0 31 0 50 3 27 3 61 3 82 3 95 3 99 3 95 3 83 3 61 3 28 2 78 2 69 4 15 3 65 2 04 2 05 2 07 1 40 1 98 2 50 2 75 2 73 2 40 1 40 1 38 1 ...

Page 58: ...OP000522 Safety 1 52 ...

Page 59: ...oor Side Latch on page 2 27 13 Cabin Storage Compartments on page 2 27 14 Hanger on page 2 28 15 Cup Holder on page 2 28 16 Emergency Glass Breaking Tool on page 2 28 Each group is explained with a point location drawing or photo and a brief description of each control switch gauge or valve Indicator lights work besides the gauges on the instrument panel The operator should monitor machine pressur...

Page 60: ...OP000523 Operating Controls 2 2 COMPONENT LOCATIONS Figure 1 1 3 25 13 4 5 2 6 7 8 16 20 22 21 24 18 23 17 15 10 26 12 11 14 9 19 FG008644 ...

Page 61: ...age 7 Dump Linkage 8 Bucket 9 Swing frame 10 Cover 11 Fuel Tank 12 Hydraulic Oil Tank 13 Canopy 14 Counterweight 15 Seat 16 Rubber Crawler Track 17 Blade 18 Blade Cylinder 19 Travel Motor 20 Lower Roller 21 Idler 22 Track Spring 23 Swing Bracket 24 Swing Cylinder 25 Attachment Control Levers 26 Air breather Reference Number Description ...

Page 62: ...OP000523 Operating Controls 2 4 OPERATOR S AREA FG008654 2 6 1 4 3 9 7 5 11 10 12 8 14 13 Figure 2 ...

Page 63: ...Right hand Work Lever Joystick See page 3 20 5 Engine Speed Control Lever See page 3 19 6 Starter Switch See page 2 8 7 Seat See page 2 23 8 Storage Compartment See page 2 27 9 Heater Optional 10 Fuse Box See page 2 19 11 Left hand Work Lever Joystick See page 3 22 12 Safety Lever See page 3 13 13 Cup Holder See page 2 28 14 Blade Lever Reference Number Description ...

Page 64: ...OP000523 Operating Controls 2 6 OPERATIONAL CONTROLS AND PANELS 5 6 11 10 9 8 4 3 2 1 7 FG008655 Figure 3 ...

Page 65: ...Speed Selector Switch 3 Work Light Switch 4 Quick Clamp Switch Optional 5 Travel Alarm Switch Optional 6 Warning Light Switch Optional 7 Cigar Lighter Optional 8 Windshield Washer Switch Optional 9 Wiper Switch Optional 10 Heater Switch Optional 11 Horn Switch Reference Number Description ...

Page 66: ... for more than fifteen seconds at a time This will help prevent damage to starter Preheat position Used to aid engine starting in cold weather When key is in this position engine preheater is operating When preheat indicator light turns ON engine preheat cycle is complete Immediately turn key to crank position and start engine This light turns ON after fifteen seconds when the starter switch is tu...

Page 67: ...l Clamp releasing for interchangeable attachments is controlled In this position the quick clamp is LOCKED The attachment is secured to the arm In this position the quick clamp is UNLOCKED The attachment is released from the arm The warning buzzer will sounds and the quick clamp indicator light will turn ON while the switch is in UNLOCKED position NOTE To move the switch pull up on the toggle and ...

Page 68: ...light push this switch to activate it O In this position the warning light is turned OFF I In this position the warning light turns ON and will start flashing 7 Cigar Lighter Optional Push the lighter all the way into the socket and release your hand After pushing it in it will be ejected when it is heated If it does not eject after a short time pull it out and have it serviced O I AXO1150L Figure...

Page 69: ...d add fluid as required NOTE If you use soapy water or synthetic detergent instead of window cleaning fluid the wiper blade or painted surfaces may be damaged Use standard window cleaning fluid SSK703 9 Wiper Switch Optional O In this position windshield wiper is turned OFF I In this position wiper runs at LOW speed II In this position wiper runs at HIGH speed NOTE Operating wiper without washer f...

Page 70: ...OP000523 Operating Controls 2 12 11 Horn Switch Press button on top of left hand work lever joystick to sound horn Figure 14 FG007495 ...

Page 71: ...iption 1 Engine Coolant Temperature Gauge 2 Fuel Gauge 3 Hour Meter 4 Engine Oil Pressure Warning Light 5 Charge Warning Light 6 Engine Coolant Temperature Warning Light 7 Air Cleaner Clogged Warning Light 8 Fuel Level Warning Light 9 Preheat Indicator Light 10 Quick Clamp Indicator Light Reference Number Description ...

Page 72: ...n the white 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 loose fan belt inspect for debris around radiator and so on 2 Fuel Gauge Shows remaining fuel quantity in tank BLUE ZONE...

Page 73: ...e engine oil pressure becomes too low the light will turn ON If this happens shut the engine down immediately and determine the cause of the problem If you continue to work when this light is ON it will result in serious engine damage 5 Charge Warning Light This indicator light will turn ON when the engine starter switch is turned ON and should go OFF after the engine starts If it does not turn OF...

Page 74: ...t This indicator light turns ON when the remaining fuel is about 6 liters 1 58 U S gal or less When this indicator light turns ON fill the tank immediately Figure 21 HAOD350L CAUTION When this light turns ON immediately stop work Allow the engine to run at low idle speed until the temperature gauge registers in the WHITE zone again When the white zone is reached allow the engine to idle for an add...

Page 75: ...urn ON when preheating is completed This light turns ON after fifteen seconds when the starter switch is turned to the preheating position 10 Quick Clamp Indicator Light This indicator light will turn ON when the quick clamp switch is in the UNLOCKED position Figure 24 FG007493 Figure 25 ...

Page 76: ... V F L TUNE AM FM CD TAPE INT 4 5 RDM 6 DN 1 SOUND 2 RPT 3 UP AST SCAN 3 1 9 8 2 5 6 1 4 10 7 FG007499 Figure 26 Reference Number Description 1 Power Volume Control 2 Sound Mode Selection 3 Band Selection 4 Tuning Up Down 5 6 Scan Function Auto Store 7 Preset Station 8 Tape Ejection 9 Tape Loading Slot 10 LCD Reference Number Description ...

Page 77: ...ates If the element of a new fuse separates check the circuit and repair the circuit Fuse Identification FG008707 Figure 27 CAUTION Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result FG007491 Figure 28 No Fuse Box Name Capacity 1 Rotating Beacon 10A 2 Spare 10A 3 Horn Travel Alarm Fuel Pump 10A 4 Quick Clamp High speed 10A 5 Cigar Li...

Page 78: ...tivated no digging operational work can be done Fusible Link A fusible link is in the engine compartment If the engine does not crank first check that the starter switch is turned ON and that no power is available No indicator lights will light Check that the A portion Figure 31 of the fusible link is not broken or burned through Replace the fusible link if damage and investigate cause Figure 29 F...

Page 79: ... Location of Vents The heater is installed on the right side of the operator s cabin If necessary the operator can control inner temperature using the temperature control switches installed on the right side of the operator s cabin Figure 32 FG008656 Heater ...

Page 80: ...LOW speed II In this position fan runs at HIGH speed Additional Operating Instructions NOTE The blower switch should be on I position If operating heater for a long time and when smoking vent the air to the outside to prevent irritation to eyes If the system is operated when the windshield is frosted or fogged over the unit will remove the moisture so normal visibility is possible Figure 33 BPO031...

Page 81: ... of the end stop will return the setting to 50 kg SEAT BELT 1 1 2 2 1 1 3 3 2 2 3 3 BTO0080L Figure 34 WARNING Seat belt is for operator s safety and should always be worn Before driving machine adjust seat to desired position for maximum comfort and machine control then fasten seat belt Seat belts must be worn across pelvic region and adjusted snugly to lessen chance and severity of injury in eve...

Page 82: ...5 into the buckle 2 Pull the belt to check that belt end is locked into buckle Adjust belt length so it is comfortably tight against the operator s pelvic region hipbone Press the button 3 Figure 36 in the center of buckle 2 and pull out belt 1 to unlock HAOB140L Figure 35 HAOB150L Figure 36 ...

Page 83: ...ndow 6 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 injury Figure 37 FG007539 WARNING When leaving operator s seat set the sa...

Page 84: ...Check that lock levers are 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 40 from cabin in direction of the arrow 2 Set bottom window in rubber holders 2 Figure 41 behind operator s seat Secure window with left and right kno...

Page 85: ... is not in use 2 To release door from side of cabin push the latch lever 2 Figure 43 down The latch lever is to the left of the operator s seat CABIN STORAGE COMPARTMENTS The large compartment 1 Figure 44 is for storing nonperishable items There is a separate small tray 2 Figure 45 on the right side of operator s seat 1 FG007543 Figure 42 2 FG000673 Figure 43 FG007545 1 Figure 44 2 FG007546 Figure...

Page 86: ... with a glass breaking tool It is to the upper left center 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 FG007547 1 Figure 46 WARNING Do not hang anything that will easily fall down or will impair your view out of the cabin FG007548 Figure 47 FG007549...

Page 87: ... 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 for loos...

Page 88: ...connectors 2 Fuel system Drain water and sediment from 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 machi...

Page 89: ...ll operation levers in NEUTRAL NOTE Be careful not to touch any switches when starting engine 4 Rotate the starter switch to the I ON position Figure 2 Charging warning light Engine oil pressure warning light Engine coolant temperature gauge Fuel gauge Lock Unlock FG007538 Figure 1 WARNING When leaving operator s seat set the safety lever to LOCK Figure 1 position if not a serious accident could o...

Page 90: ... 4 6 Follow procedures in Hydraulic System Warm up on page 3 9 7 After warming unit check all operating indicators to make sure that all engine systems oil pressure coolant etc are in the normal operating range Normal indicators are WARNING Start the engine after sounding horn and making sure that there are no people or obstacles in the area FG007557 Figure 3 FG001372 1 O I Figure 4 WARNING If the...

Page 91: ...run at low idle speed until the temperature gauge registers in the white zone again When the white 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 loose fan belt inspect for debris...

Page 92: ... LOW IDLE Figure 6 3 Sound horn 4 Turn starter switch to the ON position Figure 7 When preheat cycle is completed the preheat indicator light 1 Figure 8 will turn ON WARNING DO NOT USE STARTING FLUIDS The preheat system could cause the starting fluid to explode Starting fluids should never be used FG007557 Figure 6 FG008069 O I Figure 7 1 FG007559 Figure 8 ...

Page 93: ...five minutes and repeat above step HAOA440L Figure 10 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 94: ...f the machine e Figure 11 to be started with the other end of black cable b Figure 11 When making the last connection to upper frame be sure to connect the cable end as far away from the machine battery as possible DO NOT CONNECT DIRECTLY TO THE NEGATIVE BATTERY TERMINAL 4 Start the engine Disconnecting the Booster Battery 1 Disconnect black negative cable b Figure 11 from the machine frame first ...

Page 95: ...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 down engi...

Page 96: ...ive minutes set at the middle of the speed range without a load Figure 16 3 Set safety lever 1 Figure 17 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 FG007557 Figure 15 FG007561 Figure 16 Lock Unlock FG007562 1 Figure 17 Figure 18 FG007563 ...

Page 97: ...for 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 machine on firm level ground 2 Lower front end attachment to ground and make sure all operating controls are in NEUTRAL 3 Set safe...

Page 98: ...cumulated 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 cabin is clean 6 Check machine for loose parts Walk around machine and check for loose parts Retighten as necessary For example swivel bearing bolt should be tightened to 112 8 Nm 11 5 kg m 83 ft...

Page 99: ...rter key is tuned ON moving the joysticks may result in movement The charged accumulator in the system will provide pilot pressure for control valve spool movement NOTE If the front attachment moves when the safety lever is moved to the RELEASE UNLOCK position and all levers and pedals are in NEUTRAL return the safety lever to LOCK position shut down engine and contact your nearest DOOSAN dealer T...

Page 100: ... 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 during travel 4 Use extreme caution when reversing travel Be sure there is a clear path behind the machine 5 Make sure to operate the travel control levers ...

Page 101: ... 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 102: ...er blade all the way up 4 When possible travel on firm level ground Avoid sudden movements and sharp turns 5 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 FG007564 Figure 31 FG007571 40 50 cm Lock Unlock Figure 32...

Page 103: ...r s door on a slope Make sure door is latched FG008060 Figure 35 FG007572 20 30 Cm Figure 36 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 ...

Page 104: ...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 FG007574 Figure 38 CAUTION When using the boom and arm to lift any portion ...

Page 105: ...ard The boom arm and bucket movements and swing direction of work levers joysticks are as follows Left hand Work Lever Joystick Figure 41 and Figure 42 1 Arm dump 2 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 FG007576 Figure 40 IMPORTANT The engine s...

Page 106: ... amount of oil being supplied Right hand Work Lever Joystick Figure 41 and Figure 44 5 Boom down 6 Boom up 7 Bucket crowd 8 Bucket dump NOTE Even after stopping the engine the front and the dozer can be lowered to the ground by operating work lever joystick by setting safety lever on UNLOCK position and turning starter switch ON Right hand Dozer Lever 9 Dozer down 10 Dozer up FG007579 Figure 43 FG...

Page 107: ...m 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 47 FG007624 1 5 2 6 4 3 8 7 Figure 46 WARNING Check surrounding area before swinging When operating a lever while in auto idle do it carefully bec...

Page 108: ...gure 49 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 109: ... 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 110: ...ut force See Figure 55 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 56 to the rear See Figure 56 10 Do not excavate underneath the machine See Figure 57 FG007590 Figure 54 FG007591 Figure 55 FG007592 1 Figure 56 FG007593 Figure ...

Page 111: ... that there is adequate overhead clearance and that there is adequate ventilation See Figure 59 13 Do not use the bucket as a hammer or ramming device This is dangerous and causes damage to the front attachment See Figure 60 14 Do not dig with the excavator tracks raised This can result in structural and mechanical failures FG007594 Figure 58 FG007595 Figure 59 FG007596 Figure 60 FG007627 Figure 6...

Page 112: ... Ground 1 If a riverbed is uneven or the current is swift be especially careful Do not travel in water deeper than the upper part of the shoes on the idler end of tracks Be careful not to submerge the center joint swivel bearing or pinion gear in water mud or sand 2 On weak unstable surfaces the machine may sink keep watching the tracks and checking the riverbed surface FG007597 Figure 62 WARNING ...

Page 113: ...he center joint Swivel bearing or pinion gear are submerged in water mud or sand they need to be serviced either lubricated or in some cases rebuilt In addition any other component that is submerged such as a bucket pin should be lubricated ...

Page 114: ... operation lever unintentionally it may create a serious accident Before leaving operator s seat set safety lever on LOCK position 120 FG007608 Figure 64 WARNING Park machine 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 64 FG007609 Figure 65 FG007557 Figure 66 Lock Unlock FG007566 Figure 67 ...

Page 115: ...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 68 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 5 metric tons 5 51 U S Tons Never use it to hau...

Page 116: ...lling hydraulic breaker assemble according to drawings provided with kit 2 If breaker is taken off excavator be sure to plug and cap all hoses 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 IMPORTANT If...

Page 117: ...not drop breaker from extreme heights or damage to upper structure may result 4 Do not operate the breaker with the boom or arm cylinders fully extended bottomed out See Figure 70 Leave over 100 mm 4 in of clearance between rod end of cylinder and cylinder head This will help prevent damage to cylinders during breaker operation 5 Do not use the breaker if the hydraulic hoses vibrate excessively Se...

Page 118: ...See Figure 73 8 Operate the breaker only to the front and rear of the excavator Do not use the breaker to either side of the excavator Do not swing the breaker from side to side when operating it See Figure 74 9 Do not curl the breaker tool tip into the arm or boom when traveling or parking the excavator See Figure 75 FG007613 Figure 72 FG007614 Figure 73 FG007615 Figure 74 WARNING Operating a bre...

Page 119: ...er 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 gu...

Page 120: ... breaker 2 Releasing the pedal stops the breaker Locking the Pedal When rotating is not needed the pedal can be locked by using the prop rod 1 locking device Locking is completed when the top end of the prop 1 is positioned into pedal hole A Position for UNLOCKING B Position for LOCKING FG007599 Figure 77 1 FG007600 Figure 78 A B FG007601 Figure 79 ...

Page 121: ... in use lock pedal lock by moving it from position 3 Figure 80 to 4 Figure 80 When unlocking it move it from position 4 Figure 80 to 3 Figure 80 1 Left swing 70 2 Right swing 50 Blade Control Lever The blade control lever located on the right hand side of the driver s seat controls the operation of the blade When the lever is released it goes to the NEUTRAL position and the blade stops immediately...

Page 122: ...de or the track system 2 Do not apply a large or unbalanced off center load to the blade this can damage the blade or the track system 3 Do not strike anything with the blade while traveling This can damage the blade or track system 4 When using the blade to jack up the machine make sure the ground is even and will give good support and that the blade contacts the ground evenly 5 When the blade is...

Page 123: ...the governing factor when lifting known weights It is recommended that you feel your way into any lift as a precaution against tip over Whenever possible lift and swing payloads between the front idler area Pick and Carry The machine can pick and carry payloads without added labor We recommend when traveling with a suspended payload you evaluate the prevailing conditions and determine the safety p...

Page 124: ... 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 pendulating Pendulating can cause a change in radius A change in radius could exceed the load chart rating or cause a tip over condition 4 Govern travel speed to suit conditions 5 Avoid sudden starts and stops ...

Page 125: ...ures 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 entire machin...

Page 126: ...h cooling system periodically to keep passage clear Avoid use of 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 ...

Page 127: ... Operation of the machine can cause dust in almost any area However when in predominantly dusty or sandy areas additional precautions must be taken 1 Keep cooling system fins and cooling areas clean Blow out with compressed air if possible as 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 chec...

Page 128: ...h fresh water as soon as possible 2 Keep all exposed surfaces coated with preservative lubricating oil Pay particular attention to damaged paint surfaces 3 Keep all painted surfaces 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...

Page 129: ...ding 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 Product Identification Number P I N Location A P I N number is stamped on the main frame under the boom foot Figure 2 It is also stamped on the product identification plate...

Page 130: ...y Precautions 1 Make sure to lock out the hydraulic controls and post a notice Warning Tag that the machine is being serviced to prevent any unauthorized operation 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 pr...

Page 131: ...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 FG007565 Figure 5 Lock Unlock FG007566 Figure 6 FG007557 Figure 7 ...

Page 132: ...g maintenance work hang up a tag Do Not Touch When Performing Inspection or Maintenance on cabin door or work lever FG001364 O I Figure 8 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 9 FG007660 Inspection or Maintenance ...

Page 133: ...il Pan Engine Oil SAE 10W 30 SAE 10W 40 SAE 15W 40 Swing Drive Case Gear Oil 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 wate...

Page 134: ...ation Organization NLGI National Lubricating Grease Institute SAE Society of Automotive 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 s...

Page 135: ...e Oil Pan with Filter 5 5 liters 1 45 U S gal Cooling System 3 5 liters 0 92 U S gal Fuel Tank 30 liters 7 9 U S gal Hydraulic Oil Tank Level 30 liters 7 9 U S gal System 45 liters 11 8 U S gal Travel Reduction Device Each 0 5 liters 1 8 U S gal Symbol Description Symbol Description Lubrication Coolant Gear Oil Swing Device Travel Device Air Cleaner Element Engine Oil Fuel Filter Engine Oil Filter...

Page 136: ...OP000524 Inspection Maintenance and Adjustment 4 8 Description of Lubrication and Service Chart Figure 10 1000h 2000h 10h 50h 250h 500h 6 2 2 2 2 3 3 4 5 9 12 14 8 7 10 11 13 1 FG007707 ...

Page 137: ... 5 L V F 8 Hydraulic Oil Tank Hydraulic Oil 30 L V 9 Fuel Tank Diesel 30 L V Water Separator Water Drain 1 V 10 Engine Oil Filter Cartridge 1 F 11 Fuel Filter Cartridge 1 12 Hydraulic Oil Return Filter Element 1 F 13 Air Cleaner Outer Element 1 C Air Cleaner Inner Element 1 14 Hydraulic Oil Suction Strainer Strainer 1 F V Maintenance and Refill C Cleaning F First Time Exchange Only F100 Every 10 H...

Page 138: ...Abnormal Sounds 4 19 Check Operation of All Controls 4 19 50 Hour Weekly Service Perform All Daily Service Checks 4 20 Grease Front Attachment Pins 4 20 Grease Dozer Pins and Dozer Cylinder 4 21 Grease Boom Swing Cylinder and Bracket 4 21 Grease Swing Gear Pinion Teeth 4 21 Grease Swing Bearing 4 21 Drain Water and Sediment from Fuel Tank 4 22 Check Engine Fan Belt for Cracks Wear and Correct Tens...

Page 139: ...draulic Oil Return Filter 4 31 Change Oil in Travel Reduction Device One on Each Side of Unit 4 32 Change Hydraulic Oil Suction Filter 4 32 2 000 Hour Yearly Service Perform All Daily 50 250 500 and 1 000 Hour Service Checks 4 33 Change Radiator Coolant 4 33 Hydraulic Oil Exchange and Suction Filter Replacing 4 34 Check Alternator and Starter 4 35 Check All Rubber Antivibration Shock Mounts 4 35 P...

Page 140: ...g final level check 1 Shut down engine and wait for fifteen minutes This will allow all oil to drain back to oil pan 2 Remove dipstick 1 Figure 12 and wipe the oil off with a clean cloth 3 Insert dipstick fully in the oil gauge tube then take it out again FG000500 Figure 11 WARNING Do not remove the grease fitting until the pressure is entirely bleed off by loosening grease fitting slowly to avoid...

Page 141: ...shown in Figure 15 2 Set engine speed to LOW IDLE 3 Set safety lever to LOCK position 4 Check level gauge by opening right access door Oil level must be between marks on sight gauge Figure 13 L H FG000616 ARO1760L Figure 14 WARNING The hydraulic oil will be hot after normal machine operation Allow the system to cool before attempting to service any of the hydraulic components The hydraulic tank is...

Page 142: ...ne and wait for the hydraulic oil to cool down C Remove the right bottom cover D Drain the excess oil from drain valve at the bottom of the tank into a suitable container 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 ...

Page 143: ...s 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 Handling of Accumulator on page 4 53 for further information 5 Do not overfill the tank 6 Securely tighten cap after fueling NOTE If breather holes 3 Figure 20 in cap are clogged a vacuum may fo...

Page 144: ...2 and ring nut 1 on head 5 7 Turn fuel lever to OPEN position NOTE Lever must be pointing down Check Cooling System and Refill As Required NOTE Do not mix ethylene glycol and propylene glycol antifreeze together If the two are mixed the protection level will be reduced to the level of the ethylene glycol Figure 21 close open FG007667 Figure 22 WARNING Allow the engine to cool before releasing the ...

Page 145: ...olant to this tank Check Level of Window Washer Liquid 1 Open the back hood door and the right door 2 Check fluid level in windshield washer tank 3 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 Use standard window cleaning fluid SSK703 Inspect Cooling Fan Blade 1 An inspection of the cooling fan is requir...

Page 146: ...t the Structure for Cracks and Faulty Welds 1 During the daily walk around inspection and when greasing the machine look for any visible damage to the machine Repair or replace any damaged parts before operating the machine Check the Operation of All Switches 1 Verify the working condition of all switches before starting the engine HAOA050L Figure 26 CAUTION Hot engine components can cause burns A...

Page 147: ...ormal Sounds Check Operation of All Controls 1 With the engine at rated speed operate all the controls 2 Follow cold weather hydraulic system warm up procedures 3 Note any slow operations or unusual movements Determine the cause and repair the fault before operating IMPORTANT Cold weather operation requires that the operator fully warm up the hydraulic oil before beginning machine operation Follow...

Page 148: ...s 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 Figure 28 Reference Number Description A Boom Cylinder 2 Points B Arm Cylinder 2 Points C Boom and Boom Swing Joint 1 Point D Boom and Arm Joint 1 Point E Bucket Cylinder 2 Po...

Page 149: ...nject two or three strokes of grease through the grease fitting B Figure 30 2 Lift bucket about 20 cm 8 in from ground Turn upper body 90 at a time for two full turns greasing the swing gear pinion teeth at each stop Grease Swing Bearing 1 Inject grease through the three grease fittings C Figure 30 using a grease gun 2 Lift bucket about 20 cm 8 in from ground Turn upper body 90 at a time for one f...

Page 150: ...pect after first 50 hours of operation and every 250 hours thereafter For details See Check Engine Fan Belt Tension on page 4 25 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 24 Inspect the Track Assemblies for Proper Tension and Loose Wor...

Page 151: ...f service 2 Remove and clean rubber evacuator valve 1 Figure 33 from bottom of air cleaner housing cover 2 Figure 33 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 34 by loosening the latches 4 Remove the outer filter 3 Figure 34 from the housing Do not remove inner filter 4 WARNING Nev...

Page 152: ...perly install the air filter and cover 9 After filter service be sure to install cover with arrows pointing UP Change Engine Oil and Filter NOTE Change engine oil and filter after first 50 hours of operation or rebuild then every 250 thereafter 1 Position a larger container under the engine Remove cap 1 Figure 37 and install hose to drain the engine oil Remove hose and install cap 1 NOTE Dispose o...

Page 153: ...LE and check engine oil pressure light 6 Shut down engine Look for signs of leaks at filter Recheck oil level after fifteen minutes Check Engine Fan Belt Tension 1 Inspect every 250 hours Inspect after first 50 hours of operation 2 With the engine shut off check the tension of the fan belt by pressing downwards on the belt midway between the fan pulley and alternator pulley The belt should flex ap...

Page 154: ...ent that can be detected by the naked eye is detrimental to belt performance 5 Do not force the belts into the pulley grooves by prying with a screwdriver or pry bar This will damage the belt side cords which will cause the belts to turn and result in complete destruction of the belts in operation 6 Belts on new machines and replacement belts lose their tension as they seat into the pulley grooves...

Page 155: ...nd fill plugs 1 and 3 Figure 41 8 Repeat this procedure on the other travel reduction device Change Oil in Travel Reduction Device One on Each Side of Unit After First 250 Hours NOTE Drain and refill oil after first 250 hours of operation or rebuild and every 1 000 hours thereafter See page 4 32 Change Hydraulic Oil Return Filter After First 250 Hours NOTE Change hydraulic oil return filter after ...

Page 156: ...raulic suction filter after first 250 hours of operation or rebuild then every 1 000 hours thereafter See page 4 31 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 157: ...valve seal lips for wear or damage Replace valve if necessary Install evacuator valve with lips parallel to the cover 3 Remove outer filter 3 Figure 43 from the air cleaner housing 4 Clean the air cleaner cover and the inside of the air cleaner housing 5 Remove inner filter 4 Figure 43 6 Clean out inside of air cleaner housing Do not use compressed air to blow out housing 7 Install new inner filte...

Page 158: ...ne to the engine it may cause the engine to run in an abnormal condition Air may impact the starting capability of the engine and may also result in surging engine speeds If the machine happens to have run out of fuel or if the fuel filter has been replaced air may need to be bleed using the following procedure 1 Shut down engine 2 Fill fuel tank 3 Loosen plug 2 Figure 44 4 Turn starter switch to ...

Page 159: ...n the oil filter set 3 and O ring 4 Figure 45 7 Install all parts in reverse order 8 Run engine for ten minutes at low idle to purge air from circuit 9 Check level in hydraulic oil tank See page 4 13 Add oil if necessary 3 2 4 1 FG008650 Figure 45 WARNING The hydraulic oil will be hot after normal machine operation Allow the system to cool before attempting to service any of the hydraulic componen...

Page 160: ...ations 4 Install drain plug 2 Figure 47 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 7 for capacity 5 Repeat this procedure on the other travel reduction device Change Hydraulic Oil Suction Filter NOTE Change hydraulic suction filter after first 250 hours of operation...

Page 161: ...gain to allow water to completely circulate 9 After allowing engine to cool drain water and fill system with proper antifreeze mixture for ambient temperature Refer to coolant concentration table See Antifreeze Concentration Tables on page 4 52 10 Run engine without radiator cap installed so all air will be purged from system Fill radiator to fill neck 11 Drain and fill radiator coolant recovery t...

Page 162: ...e pressurized air from hydraulic tank by rotating breather cap 1 Figure 51 Figure 50 ARO1760L WARNING The hydraulic oil will be hot after normal machine operation Allow the system to cool before attempting to service any of the hydraulic components The hydraulic tank is pressurized Loosen the breather cap to allow the pressurized air to vent After the pressure has been released it is safe to remov...

Page 163: ...ove bolts and cover 2 Figure 53 from top of hydraulic oil tank 7 Remove the suction filter 3 8 Install new suction filter Fill the hydraulic oil tank Check level using sight gauge on side of tank 9 Install all parts in reverse order Check Alternator and Starter These checks need to be completed by an authorized DOOSAN dealer Check All Rubber Antivibration Shock Mounts FG000129 FG007690 Figure 52 I...

Page 164: ... Maintenance and Adjustment 4 36 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 ...

Page 165: ...e intervals even if the old parts look good Always replace all related parts such as gaskets and O rings Use only original equipment manufacturers parts Major Component Parts Name to be Exchanged Periodically Time to Exchange Engine Fuel hose Tank to filter 2 years or 4 000 hours Fuel hose Tank to fuel injection pump Heater hose Heater to engine Hydraulic System Body Pump suction hose Return hose ...

Page 166: ... 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 37 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 167: ...gine bracket Fan Side 12 8 19 107 8 11 80 Pump Side 12 8 19 107 8 11 80 3 Hydraulic and fuel tank mounting bolts 10 8 17 49 5 36 4 Hydraulic hose and pipe joint PF1 4 26 5 29 4 2 7 3 0 20 22 PF3 8 46 51 4 7 5 2 34 38 PF1 2 56 62 5 7 6 3 41 46 5 Pump mounting bolt 12 2 19 88 2 9 65 6 Pump housing bolt 10 8 17 63 7 6 5 47 7 Control valve mounting bolt 8 4 13 21 56 2 2 16 8 Control valve base mountin...

Page 168: ...at tooth wear or breakage has not developed Do not allow the replaceable bucket teeth to wear down to the point that the bucket is exposed See Figure 54 WARNING Due to the possibility of flying metal objects always wear safety helmet protective gloves and eye protection when changing bucket teeth Curl the bucket upwards and place the round rear surface of the bucket firmly on the ground Shut the e...

Page 169: ...on 3 Check tooth point and side cutter for wear or looseness 4 Tighten tooth points and side cutters or replace if damaged A Remove nuts 1 washers 2 and bolts 3 Remove side cutters 4 Each side cutter has three sets of bolts and nuts B Remove nuts 5 and bolts 6 Remove tooth point A tooth point has two sets of bolts and nuts C Reinstall parts in reverse order of disassembly D After the first operati...

Page 170: ...e the arm or bucket link 4 out of the way 4 Remove the old O ring and temporarily install the new O ring 1 onto the bucket bushing 2 Make sure that the O ring groove on both the bucket link 4 and bushing have been cleaned 5 Realign the arm or link with the bucket pin hole and insert the bucket pin 3 WARNING Due to possibility of flying metal objects always wear safety helmet protective gloves and ...

Page 171: ...OP000524 4 43 Inspection Maintenance and Adjustment 6 Roll the new O ring 1 into the O ring groove 1 FG007697 Figure 59 ...

Page 172: ...ide clearance under O rings at attachment point Clearance should be between 0 2 0 7 mm 0 008 0 027 in on each end of arm boss between side face of boss and inside edge of ear busing Too tight a fit can cause excessive wear while too much clearance may produce excessive noise and potentially hazardous slack control 3 Recheck end play by forcing bucket towards opposite side and repeating clearance m...

Page 173: ...tall new bucket as shown in illustration 3 Install pins aligning arm hole A with dump link hole B Install O rings 4 Apply grease to pins 5 Run engine at low idle and move bucket slowly through one stroke to make sure parts are installed correctly WARNING When removing pin metal pieces can fly out and cause injury Be sure to wear safety glasses or goggles safety hat and safety gloves to prevent inj...

Page 174: ...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 175: ...nd water will neutralize acid on the battery surface terminals and cable connectors Petroleum jelly or grease can be applied to the connectors to help prevent corrosion Battery Replacement When the charging indicator indicates transparency state replace the battery Fuses 1 The fuses in the fuse box are used to protect the various electrical circuits and their components from being damaged See Figu...

Page 176: ...he element separates If the element of a new fuse separates check the circuit and repair the circuit Fuse Identification FG008707 Figure 65 CAUTION Always replace fuses with the same type and capacity fuse that was removed Otherwise electrical damage could result FG007491 Figure 66 No Fuse Box Name Capacity 1 Rotating Beacon 10A 2 Spare 10A 3 Horn Travel Alarm Fuel Pump 10A 4 Quick Clamp High spee...

Page 177: ...tifreeze with 60 distilled water for adding additional fluid to the system during normal maintenance This level will help maintain the additive concentration of the system Check the coolant every 500 hours Engine overheating is often caused by bent or clogged radiator fins The spaces between the fins can be cleaned by use of air or water under pressure When straightening bent fins use care not to ...

Page 178: ... 1 liter 1 U S quart it from the radiator into a clean plastic container NOTE Do not take the sample from the coolant recovery tank Recovery tank coolant concentration can differ from the concentration level of coolant in the radiator 2 Dip test strip into coolant sample for 3 5 seconds Remove strip and excessive coolant by giving the strip one shack 3 Wait for 45 seconds for the test strip to cha...

Page 179: ...els A If anticorrosive additive level is below 0 3 add 100 pure antifreeze to the radiator B If anticorrosive additive level is greater 0 8 add a 50 distilled water and antifreeze mixture to lower the additive reading NOTE In either case keep the antifreeze concentration level between 33 and 50 6 Run the engine to recirculate the coolant mixture Be sure that engine reaches operating temperature to...

Page 180: ...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 181: ...n released from the circuit To release pressure turn the starter switch to the I ON position and operate all hydraulic control levers and forward reverse travel levers Even though the engine is shutdown hydraulic actuated components may move while releasing pilot pressure Keep all personnel away from excavator while performing this operation Set safety lever on LOCK position after stopping engine ...

Page 182: ...ocedures 2 Apply a coating of light oil to the exposed plated metal surfaces such as hydraulic cylinder rods etc 3 Apply a coating of light oil to all the control linkages and control cylinders control valve spools etc Battery 1 Remove the battery from the excavator and store in a warm place Fully charge battery before storing Cooling System 1 Inspect the coolant reserve tank to make sure that the...

Page 183: ...ntake strainer and fuel filter more frequently 4 Inspect and clean the starter and alternator as required Operating in rocky terrain 1 Check the undercarriage and wheel drive assemblies for damage or excessive wear 2 Inspect for loose or damaged fittings or bolts 3 Inspect wheels and tires for damage 4 On a more frequent basis inspect the front end attachments for damage or excessive wear 5 Instal...

Page 184: ... 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 to prevent...

Page 185: ...k tension to decrease Loosen valve slowly a maximum of 1 to turns 2 When crawler tension is correct tighten cartridge valve to 59 88 Nm 6 9 kg m 43 65 ft lb 3 Recheck tension by moving track forward and backward 4 Recheck tension and adjust as necessary Figure 72 Figure 73 WARNING The track adjusting mechanism is under very high pressure NEVER release pressure too suddenly The grease cylinder valv...

Page 186: ...will pressurize the hydraulic oil tank and system 5 Slowly loosen vent plug Figure 76 several turns until hydraulic oil flows out of plug This shows that air has been released 6 Tighten the plug Figure 76 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 Rep...

Page 187: ...r 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 all systems have been vent and purged of air Set engine speed to LOW IDLE and check hydraulic...

Page 188: ...OP000524 Inspection Maintenance and Adjustment 4 60 ...

Page 189: ...etting 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 ...

Page 190: ...ss than or not exceeding a 15 angle Ramps steeper than this may cause a problem when loading or unloading 4 Set the travel speed selector switch to O OFF position See Figure 2 5 Set engine speed to LOW IDLE 6 If the machine is equipped with work equipment set the work equipment at the front and travel forward to load it 7 Extend bucket and arm cylinders to maximum length and then lower the boom sl...

Page 191: ... blocking 1 Figure 7 in front of and behind each track Use chains or cable tie downs 2 as required by local transportation laws 12 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 Lock Unlock FG007566 Figure 5 FG0013...

Page 192: ...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 FG008073 Figure 8 WARNING Improper lifting can allow load to shift and cause injury or damage ...

Page 193: ...ponents without first consulting a DOOSAN distributor CONTROL VALVE Problem Possible Cause Remedy Fails to bear load Leaky spool Replace valve housing assembly relief valve Leaky port relief valve Disassemble clean or replace port Load drops when control is moved from neutral to UP Foreign material in load check valve Disassemble and clean load check valve Damaged poppet or seal in load check valv...

Page 194: ...cracked or damaged Replace Problem Possible Cause Remedy Problem Possible Cause Remedy Pressure does not rise Poppet sticking open Disassemble and clean Pressure unstable Damaged pilot poppet seal Replace damaged parts Main poppet of pilot piston sticking Disassemble clean and remove surface pitting Abrupt rise and fall in pressure Wear due to foreign material Replace worn parts Locknut and adjust...

Page 195: ...lic pump Bad main relief valve Adjust pressure or replace Low level of hydraulic oil Add oil Wrong viscosity hydraulic oil Replace with correct viscosity Suction filter restricted Replace filter Poor overall performance Hydraulic pump failure Replace hydraulic pump Hydraulic oil level low Add oil Lack of power Main or port relief valve pressure set too low Adjust pressure Damaged hydraulic cylinde...

Page 196: ...ve high temperature Reduce oil temperature Air in system Bleed Oil leak from inside motor Replace motor Unusual sound from hydraulic motor Hydraulic oil level low Add oil Air in motor Retighten fittings on suction side Wear and damage inside hydraulic motor Replace motor Shaft not properly installed Readjust shaft Problem Possible Cause Remedy Lack of cylinder power Relief valve pressure set too l...

Page 197: ...ow oil level Tighten fittings and add oil Cavitation due to high viscosity oil Replace oil Pump and engine not aligned Readjust shaft Air in hydraulic oil Bleed Oil leak from outside pump Bad hydraulic pump seal Replace seal or pump Problem Possible Cause Remedy Swing power weak Hydraulic motor performs poorly Replace hydraulic motor Swing bearing seized Grease or replace swivel bearing Braking po...

Page 198: ...lve housing assembly Travel not smooth Tracks tension low Adjust tension Stone s jammed in track Remove Counterbalance valve bad Replace valve Hydraulic motor performs poorly Replace hydraulic motor Air in hydraulic motor Add oil Machine wanders does not travel straight Tracks have different tension Adjust so tracks have equal tension Hydraulic pump performs poorly Replace hydraulic pump Hydraulic...

Page 199: ...ion Length 4 043 mm Height 2 465 mm Height Boom 1 488 mm Width 1 620 mm Performance Max digging force Bucket 2 020 kgf 1 637 kgf 2 020 kgf 1 637 kgf Arm 1 404 kgf 1 283 kgf 1 263 kgf 1 164 kgf Traveling speed 1 speed 2 4 km h 2 speed 4 3 km h Swing speed 9 63 rpm Drawbar pull 2 400 kg Hydraulic pump Type Variable displacement axial piston pump Max flow rate 26 4 x 2 liters min 18 9 liters min Gear...

Page 200: ...OP000473 Specification 7 2 OVERALL DIMENSIONS A B D E F M K L G O N H I U T S R Q P J C 5 0 7 0 FG007625 Figure 1 ...

Page 201: ...2 C 760 mm 2 6 D 3 083 mm 10 1 E 1 488 mm 4 11 F 355 mm 1 2 G 340 mm 1 1 H 1 451 mm 4 9 I 1 550 mm 5 10 J 1 970 mm 6 6 K 2 411 mm 7 11 L 520 mm 1 8 M 1 440 mm 4 9 N 1 030 mm 3 5 O 1 015 mm 3 4 P 2 465 mm 8 1 Q 288 mm 11 3 in R 440 mm 1 5 S 300 mm 11 8 in T 1 270 mm 4 2 U 1 570 mm 5 2 ...

Page 202: ...OOM 1 1 m 3 6 ft ARM 1 3 m 4 26 ft ARM A Max digging radius 4 504 mm 14 9 4 690 mm 15 5 B Max vertical digging depth 2 058 mm 6 9 2 250 mm 7 5 C Max digging depth 2 490 mm 8 2 2 690 mm 8 10 D Max dump height 2 773 mm 9 1 2 885 mm 9 6 E Max digging height 4 164 mm 13 8 4 277 mm 14 0 F Min digging radius 1 949 mm 6 5 1 983 mm 6 6 ...

Page 203: ...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 204: ...295 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 Sulfur broken 529 kg m3 1 620 lb yd3 MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3...

Page 205: ... Cold Weather Starting 3 6 Component Locations 2 2 Control Lever 6 3 Control Valve 6 1 Cooling System Engine 4 49 Radiator Coolant 4 33 Refill Cooling System 4 16 Cracks and Faulty Welds 4 18 Cup Holder 2 28 Cycle Time Tests 4 36 D Description of Lubrication and Service Chart 4 8 Door Side Latch 2 27 E Electrical System 4 46 Emergency Glass Breaking Tool 2 28 Engine 2 15 Adjust Valve Clearance 4 3...

Page 206: ...2 Inspection Maintenance and Adjustment 4 1 L Leaks in the Fuel System 4 15 Leaks in the Hydraulic System 4 14 Levers Adjusting the Seat Forward 2 23 Adjusting the Seat s Angle 2 23 Lifting 3 37 Lifting With Sling 5 4 Lights Cabin 2 20 Loading and Unloading 5 1 Locations of Safety Labels 1 5 Long Term Storage 4 54 Lubrication and filters 3 2 Lubrication and Service Chart 4 7 M Maintenance Interval...

Page 207: ...trainer 4 34 Swing Bearing 4 21 System 6 5 Switches Engine Speed Control 3 19 Heater Switch 2 11 Horn Switch 2 12 Pilot Cutoff Switch 2 20 Quick Clamp Switch 2 9 Starter Switch 2 8 Travel Speed Control 3 14 Travel Speed Selector Switch 2 8 Warnin Light 2 10 Windshield Washer 2 11 Wiper 2 11 Work Light Switch 2 9 T Table of Recommended Lubricants 4 5 Towing Procedure 3 29 Track Assemblies 4 22 Trav...

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