Doosan DX700LC Operation And Maintenance Manual Download Page 293 | Manualshive

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6-1

Troubleshooting

OP000030

6

Troubleshooting

Anytime that a malfunction occurs, take immediate corrective
action. Check for and investigate the cause of the malfunction. A
schedule maintenance program can prevent malfunctions from
occurring by doing preventative maintenance. A systematic
approach should be taken to troubleshooting, since several
overlapping malfunctions may give the appearance of a problem
that does not exist. If cause for the malfunction cannot be
determined, contact your DOOSAN distributor. Never perform
an adjustment of or disassembly of, hydraulic components,
electrical and electronic components, without first consulting a
DOOSAN distributor.

ELECTRICAL SYSTEM

Problem

Cause

Remedy

Battery will not hold a
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.

Replace control dial.

Throttle controller failed.

Replace controller.

Speed control motor failed.

Repair or replace as required.

Blown fuse.

Replace fuse.

Wiring harness damaged.

Repair or replace as required.

Connector failed.

Repair or replace as required.

Power mode selector does
not work.

Blown fuse.

Replace fuse.

Power mode selector switch failed.

Replace switch.

Connector failed.

Replace connector.

Wiring harness damaged.

Repair or replace as required.

e-EPOS controller failed.

Repair or replace as required.

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Summary of Contents for DX700LC

Page 1: ...mmended 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 equip...

Page 2: ......

Page 3: ...28 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 2 Operator s Area 2 4 Operational Controls and Panels 2 6 Instrument Panel 2 20 Multifunction Gauge and Graphic Information 2 27 Mode Selector Buttons 2 33 Setting Main Menu 2 35 Flow Control 2 44 Operation Selection Display 2 46 Heate...

Page 4: ...3 1 Starting and Stopping the Engine 3 2 Safety Lever 3 13 Travel 3 14 Operating Instructions 3 19 Operating Precautions 3 25 Parking Excavator 3 30 Towing Procedure 3 31 Hydraulic Breaker 3 32 Adjusting the Pump Flow 3 37 Operating Techniques 3 40 Operation Under Unusual Conditions 3 42 Inspection Maintenance and Adjustment 4 1 Preventive Maintenance 4 1 Preliminary Work Machine Setup for Mainten...

Page 5: ...ction 4 58 Bucket 4 71 Bucket Shimming Procedures 4 73 Electrical System 4 74 Engine Cooling System 4 78 Fuel Transfer Pump Optional 4 83 Handling of Accumulator 4 85 Track Tension 4 86 Venting and Priming Hydraulic System 4 88 Long Term Storage 4 90 Maintenance in Special Conditions 4 92 Transportation 5 1 Disassembly and Assembly Before and after Transportation 5 1 Loading and Unloading 5 6 Lift...

Page 6: ...950106 00012E Table of Contents IV Specification 7 1 Approximate Weight of Workload Materials 7 6 Index 8 1 ...

Page 7: ...fications on page 1 16 4 General Hazard Information on page 1 16 5 Before Starting Engine on page 1 25 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: ...e 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 has been shipped If this machine has been purchased in another country or purchased from someone in another country it may lack certain safety devices and spec...

Page 9: ...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 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...

Page 10: ...OP001120 Safety 1 4 LOCATION OF SAFETY LABELS FG016159 19 15 6 5 3 14 13 14 7 11 12 14 9 1 2 10 16 18 18 4 Figure 1 ...

Page 11: ...u cannot read the 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 s...

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 FG014682 190 00094 Sudden and unwanted machine movement can cause serious injury or death Always make sure when lea...

Page 15: ...an be 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 FG012964 HOT OIL CAN CAU...

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: ...n Inspection and Maintenance 190 00695A 190 00098A 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 FG011223 190 00098A DO NOT OPERATE when performing inspection WARNING 190 00695A or maintenance ...

Page 18: ...1120 Safety 1 12 13 Warning for a Hot Surface 190 00648A 14 Caution for Hood 190 00522A 15 Keep Out of the Swing Area 2190 3379A K1008571 190 00648 ARO1210L 190 00522A FG012965 2190 3379A K1008571 FG006551 ...

Page 19: ...arning for Engine ECU K1012583 ARO1230L 190 00652 electrical welding to the body structure To prevent damage to ECU of engine by Be sure to read the procedures described carefully before electrical welding in the Operation and Maintenance manual K1012583 CAUTION FG014331 ...

Page 20: ...OP001120 Safety 1 14 18 Warning for Lifting Tie Down K1042074A 19 Warning for Tie Down 950209 00205 K1042074A FG014828 950209 00205 FG014875 ...

Page 21: ...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 22: ...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 23: ...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 24: ...2 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 particular application 2 Replace...

Page 25: ...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 that you support yourself secu...

Page 26: ...le 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 under p...

Page 27: ...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 28: ... 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 distributor for available safety guar...

Page 29: ...escribe in Handling of Accumulator on page 4 86 The accumulator is charged with high pressure nitrogen gas so it is extremely dangerous if it is handled in the wrong way Always observe the following precautions Do not drill or make any holes in the accumulator or expose it any flame fire or heat source Do not weld on the accumulator or try attaching anything to it When carrying out disassembly or ...

Page 30: ...rator 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 point to break the glass FG000178 Figure 13 WARNING Protect your eyes when breaking the glass ...

Page 31: ...ject 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 near bridges phone lines work site scaffolds or other obstructions Minimum levels of insurance coverage work permits or certification physical barriers around the work site or restricted hours of operation may be mandated by govern...

Page 32: ...gle of the mirrors and check that the safety lever is in LOCKED position If any abnormalities are found in the above checks carry out repairs immediately Engine Starting Walk around your machine before getting in the operator s cabin Look for evidence of leaking fluid loose fasteners misaligned assemblies or any other indications of possible equipment hazard All equipment covers and machinery safe...

Page 33: ...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 rear view mirrors for best visibility close to the m...

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: ...he bucket to the ground to help stop the machine Do not travel on grass fallen 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 oper...

Page 37: ...r inadequate supports when work is being done Block tracks fore and aft to prevent any movement When using the machine to prevent accidents caused by damage to the work equipment and overturning because of an excessive load do not use the machine in excess of its ability in terms of the maximum load and stability determined by the structure of the machine When working at the edge of an excavation ...

Page 38: ...s indoors or in crowded areas Do not pass the bucket over the heads of workers or over the operator s compartment of dump truck Avoid High Voltage Cables Serious injury or death can result from contact or proximity to high voltage electric lines The bucket does 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 li...

Page 39: ...efully on Snow Ice and in Very Cold Temperatures In icy cold weather avoid sudden travel movements and stay away from even slight slopes The machine could skid off to one side very easily Snow accumulation could hide or obscure potential hazards Use care while operating or while using the machine to clear snow Warming up the engine for a short period may be necessary to avoid operating with sluggi...

Page 40: ...f If parking on inclines is unavoidable block the crawler tracks to prevent movement Lower the bucket or other working attachment completely to the ground or to an overnight support saddle There should be no possibility of unintended or accidental movement When parking on public roads provide fences signs flags or lights and put up any other necessary signs to ensure that passing traffic can see t...

Page 41: ...nger 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 mu...

Page 42: ... 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 not smoke while you refuel the machine or while you are in a refueling area Do not smoke in battery charging areas or in areas the contain f...

Page 43: ... 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 filter plug is cool before you remove it with your bare hand Remove the hydraulic tank filter plug slowly to relieve pressure Relieve all pr...

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: ...cut off switch 7 Reassemble the undercover under the engine 8 Close the cover of the battery Warning for Counterweight and Front Attachment Removal Figure 36 FG015761 ON OFF Figure 37 FG015762 1 1 Figure 38 FG015763 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 unexpect...

Page 46: ...ng Do not spill oil or grease Do not leave tools laying about Watch your step when walking Never jump down from the machine When getting on or off the machine use the steps and handrails and maintain 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 wor...

Page 47: ...oose retainer pin can injure personnel Make sure that the area is clear of people when you strike a retainer pin To avoid injury to your eyes wear protective glasses when you strike a retainer pin 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...

Page 48: ...ressurized 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 correctly ...

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: ...nd right 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 carr...

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: ...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 48 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 55: ...ined 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 49 The weight of slings and any auxiliary lifting device and or the weight difference of any attachment heavier than standard configuration mus...

Page 56: ...6 70 14 44 13 76 10 63 1 5 23 51 19 3 17 89 13 62 14 47 10 12 0 28 31 28 31 24 09 18 59 18 47 13 07 14 81 9 76 1 5 24 16 24 16 31 18 30 2 23 53 18 35 18 27 12 82 14 58 9 58 3 32 85 32 85 28 23 28 23 21 85 18 45 17 14 12 83 13 46 9 63 4 5 30 06 30 06 23 82 23 82 18 80 18 80 14 66 13 14 6 17 10 17 10 13 53 13 53 A m 10 5 MAX REACH B m A m 9 8 38 8 38 9 15 7 5 8 23 8 23 9 78 6 9 72 8 61 8 34 8 34 10 ...

Page 57: ... 55 38 67 29 3 31 32 21 74 0 64 51 64 51 52 13 39 96 39 94 28 11 32 03 20 96 5 54 04 54 04 67 72 64 66 50 96 39 4 39 50 27 55 31 45 20 59 10 73 64 73 64 61 22 61 22 47 25 39 63 36 95 27 59 28 82 20 72 15 64 94 64 94 51 36 51 36 40 40 40 40 31 25 28 32 20 36 15 36 15 28 29 28 29 A ft 35 MAX REACH B ft A m 30 18 55 18 55 29 66 25 18 14 18 14 32 75 20 18 36 18 36 34 85 15 24 84 17 83 19 15 16 67 36 1...

Page 58: ...2 3 22 17 19 81 16 95 13 95 13 90 10 27 1 5 23 52 18 63 17 91 13 18 14 45 9 81 0 23 62 18 09 18 21 12 72 14 59 9 5 1 5 29 07 29 07 22 62 18 01 17 71 12 56 14 08 9 4 3 30 81 30 81 25 80 25 80 20 52 18 26 16 19 12 69 12 45 9 57 4 5 24 55 24 55 20 93 20 93 16 92 16 92 13 03 13 03 6 10 46 10 46 A m 10 5 MAX REACH B m A m 9 10 66 10 66 8 60 7 5 10 46 10 31 9 55 6 10 62 8 78 10 19 4 5 11 59 8 11 10 7 87...

Page 59: ...03 30 09 22 06 5 50 81 40 11 38 72 28 37 31 26 21 06 0 60 08 60 08 51 15 38 89 39 39 27 35 31 52 20 41 5 63 27 63 27 49 02 38 68 38 28 27 30 32 20 21 10 67 35 67 35 56 01 56 01 44 38 39 22 34 85 27 3 15 53 05 53 05 45 10 45 10 36 27 36 27 27 51 27 51 20 21 17 21 17 A ft 35 MAX REACH B ft A m 30 23 59 23 59 27 85 25 23 06 23 06 31 12 20 23 37 19 52 33 33 15 24 41 17 43 34 67 10 25 80 16 54 25 63 16...

Page 60: ... 32 47 30 04 23 85 18 33 18 35 12 79 3 24 86 24 86 29 49 29 49 30 12 30 12 22 70 18 28 17 65 12 69 4 5 31 53 31 53 35 41 35 41 26 36 26 36 20 30 18 54 15 83 12 86 6 26 54 26 54 20 65 20 65 16 11 16 11 12 12 12 12 A m 9 10 5 MAX REACH B m A m 9 6 67 6 67 9 94 7 5 10 55 10 55 8 17 8 17 6 51 6 51 10 78 6 11 23 11 23 10 34 8 82 6 56 6 56 11 35 4 5 12 16 11 42 10 83 8 49 6 79 6 74 11 70 3 13 17 10 8 11...

Page 61: ...3 55 33 66 09 66 09 65 24 64 77 49 09 39 25 38 10 27 27 15 70 41 70 41 76 49 76 49 56 88 56 88 43 70 39 85 33 93 27 68 20 56 53 56 53 44 00 44 00 34 16 34 16 25 22 25 22 A ft 30 35 MAX REACH B ft A m 30 14 77 14 77 32 32 25 23 04 23 04 15 11 15 11 14 36 14 36 35 17 20 24 41 24 41 22 57 18 82 14 44 14 44 37 13 15 26 38 24 52 23 55 18 16 14 93 14 91 38 33 10 28 52 23 18 24 71 17 38 15 86 14 02 38 85...

Page 62: ...2 73 24 45 20 54 18 94 14 41 15 53 10 67 13 18 9 62 9 56 0 34 68 31 87 25 16 19 78 19 40 13 92 15 52 10 41 14 93 9 95 9 26 1 5 36 17 36 17 32 71 31 81 24 40 19 52 18 81 13 72 15 34 10 96 8 68 3 38 29 38 29 28 79 28 79 21 90 19 7 16 53 13 89 15 56 13 17 7 78 4 5 28 12 28 12 22 07 22 07 16 56 16 56 15 02 15 02 6 40 A ft 10 15 20 25 30 MAX REACH B ft A m 25 31 14 31 14 22 15 22 15 26 86 20 32 69 32 6...

Page 63: ... 93 15 12 10 89 13 08 10 1 9 37 1 5 24 60 20 29 19 02 14 24 15 52 10 53 14 91 9 93 9 31 0 34 20 31 67 25 03 19 62 19 30 13 8 15 31 10 32 15 30 10 31 9 00 1 5 37 60 37 60 31 83 31 76 23 98 19 45 18 46 13 67 15 65 11 46 8 41 3 35 52 35 52 27 52 27 52 21 09 19 72 15 74 14 7 48 4 5 24 91 24 91 20 18 20 18 14 91 14 91 14 78 14 78 6 03 A ft 10 15 20 25 30 MAX REACH B ft A m 25 30 35 30 35 24 55 24 55 25...

Page 64: ... 16 58 16 49 12 71 1 5 26 67 21 84 20 75 15 91 17 13 12 3 0 26 91 21 33 21 16 15 49 17 34 12 02 1 5 29 60 29 60 25 98 21 21 20 71 15 32 16 88 11 9 3 28 89 28 89 29 77 29 77 23 89 21 36 19 22 15 39 15 32 12 4 5 29 51 29 51 24 82 24 82 20 28 20 28 16 10 15 73 6 17 17 17 17 13 88 13 88 A m 10 5 MAX REACH B m A m 9 12 01 12 01 9 04 7 5 11 57 11 57 9 95 6 12 36 10 51 11 47 10 39 10 56 4 5 14 08 10 32 1...

Page 65: ...7 4 5 57 70 47 08 44 94 34 33 37 15 26 51 0 58 34 45 94 45 84 33 4 37 56 25 91 5 67 61 67 61 56 36 45 64 44 86 33 03 36 46 25 68 10 65 11 65 11 64 67 64 67 51 74 45 98 41 50 33 19 32 74 25 95 15 63 87 63 87 53 59 53 59 43 61 43 61 34 27 34 20 28 72 28 72 A ft 35 MAX REACH B ft A m 30 26 61 26 61 29 32 25 25 55 25 55 32 43 20 25 28 23 04 34 55 15 30 72 22 17 25 64 21 28 35 84 10 31 31 21 67 26 61 2...

Page 66: ... 49 17 49 15 57 13 42 4 5 23 67 23 67 18 92 17 07 16 24 13 3 20 24 16 29 16 92 12 56 1 5 21 05 15 72 17 36 12 2 0 26 56 21 21 21 10 15 4 17 29 11 99 1 5 25 09 21 23 20 24 15 33 16 40 11 97 3 28 80 28 80 26 91 26 91 22 44 21 5 18 18 15 52 4 5 21 38 21 38 18 00 18 00 13 72 13 72 A m 10 5 MAX REACH B m A m 9 15 81 15 56 8 36 7 5 15 19 12 79 9 34 6 14 88 11 24 9 99 4 5 14 74 10 35 10 39 3 14 46 9 99 1...

Page 67: ...8 15 51 00 51 00 40 96 36 85 35 30 28 01 10 43 81 35 17 36 73 27 08 5 58 36 46 36 45 59 33 91 37 63 26 32 0 57 66 45 67 45 73 33 21 37 42 25 87 5 65 16 65 16 54 48 45 69 43 84 33 06 35 32 25 86 10 63 40 63 40 58 59 58 59 48 61 46 29 39 17 33 49 15 46 09 46 09 38 53 38 53 28 36 28 36 A ft MAX REACH B ft A m 30 35 05 35 05 27 08 25 33 55 28 55 30 43 20 32 83 24 94 32 68 15 32 51 22 89 34 04 10 31 64...

Page 68: ...4 21 99 20 10 15 95 16 62 12 27 0 26 67 21 26 20 82 15 42 17 06 11 91 1 5 28 46 28 46 26 29 20 97 20 76 15 14 16 94 11 72 3 25 99 25 99 31 78 31 78 24 77 21 19 76 15 1 15 97 11 71 4 5 35 12 35 12 27 50 27 50 21 88 21 31 17 47 15 32 13 42 11 97 6 21 02 21 02 16 92 16 92 12 68 12 68 A m 10 5 MAX REACH B m A m 9 9 79 9 79 9 8 7 5 10 74 10 74 9 45 9 45 10 64 6 12 95 10 62 9 36 9 36 11 22 4 5 13 38 10 ...

Page 69: ...04 26 44 0 57 77 45 8 45 10 33 23 36 98 25 67 5 64 88 64 88 57 00 45 14 44 96 32 63 36 64 25 26 10 58 49 58 49 68 95 68 95 53 63 45 19 42 71 32 56 34 37 25 27 15 75 96 75 96 59 40 59 40 47 16 45 89 37 47 33 06 28 11 25 95 20 44 75 44 75 35 79 35 79 25 95 25 95 A ft 35 MAX REACH B ft A m 30 21 69 21 69 31 85 25 20 86 20 86 34 73 20 28 34 22 78 20 63 20 63 36 71 15 29 17 22 26 20 87 19 33 37 93 10 3...

Page 70: ...3 82 20 90 17 14 17 88 13 08 15 43 12 22 9 41 1 5 27 69 22 86 21 83 16 58 18 13 12 79 16 69 12 11 9 35 0 27 86 22 36 21 93 16 24 17 62 12 64 17 49 12 57 9 04 1 5 34 13 34 13 26 43 22 26 20 75 16 16 17 44 13 79 8 45 3 36 04 36 04 29 20 29 20 22 96 22 53 17 01 16 48 16 88 16 42 7 52 4 5 20 81 20 81 15 21 15 21 14 72 14 72 6 08 A ft 10 15 20 25 30 MAX REACH B ft A m 25 39 11 39 11 32 69 32 69 26 06 2...

Page 71: ... 20 06 17 76 16 64 13 45 8 96 3 26 59 23 7 21 28 17 11 18 16 13 08 17 43 12 75 9 15 1 5 27 96 22 83 22 05 16 59 18 21 12 84 17 99 12 66 9 09 0 27 82 22 41 21 93 16 3 18 04 13 18 8 77 1 5 33 15 33 15 26 03 22 39 20 38 16 29 17 87 14 58 8 16 3 32 89 32 89 27 80 27 80 22 03 22 03 17 04 17 04 7 19 4 5 18 48 18 48 14 04 14 04 5 68 A ft 10 15 20 25 30 MAX REACH B ft A m 25 37 58 37 58 37 05 37 05 25 05 ...

Page 72: ...OP001120 Safety 1 66 ...

Page 73: ...tch on page 2 65 15 Cabin Storage Compartments on page 2 66 16 Ashtray on page 2 66 17 Sun Visor on page 2 67 18 Hanger on page 2 67 19 Cup Holder on page 2 68 20 Door Window Holder on page 2 68 21 Emergency Glass Breaking Tool on page 2 68 22 Miscellaneous Access Covers and Doors on page 2 69 Each group is explained with a point location drawing or photo and a brief description of each control sw...

Page 74: ...OP001121 Operating Controls 2 2 COMPONENT LOCATIONS Figure 1 18 39 38 17 34 33 36 35 37 1 2 3 4 5 6 7 8 9 10 11 12 13 14 25 24 23 22 26 27 28 29 30 31 32 21 20 19 15 16 FG015770 ...

Page 75: ...rweight 14 Muffler 15 Return Filter 16 Pumps 17 Fuel Pre filter 18 Hydraulic Oil Tank 19 Suction Filter 20 Travel Motor 21 Track Link and Shoe 22 Track Guard 23 Upper Roller 24 Lower Roller 25 Cabin 26 Track Adjuster 27 Work Lever Controls Joystick 28 Seat 29 Center Joint 30 Idler 31 Travel Lever 32 Swing Bearing 33 Bucket 34 Push Link 35 Guide Link 36 Bucket Cylinder 37 Arm 38 Tooth Point 39 Batt...

Page 76: ...OP001121 Operating Controls 2 4 OPERATOR S AREA 1 3 2 5 4 9 8 16 15 14 13 12 7 6 10 11 17 FG013745 18 19 20 Figure 2 ...

Page 77: ... Dial See page 2 8 8 Heater and Air Conditioner Control Panel See page 2 49 9 Starter Switch See page 2 8 10 Seat See page 2 58 11 Storage Compartment See page 2 66 12 Heater and Air Conditioner Unit 13 Stereo See page 2 55 14 Fuse Box See page 2 57 15 Left hand Work Lever Joystick See page 3 22 16 Safety Lever See page 3 13 17 Storage Compartment See page 2 66 18 DMS Laptop Computer Connector 19 ...

Page 78: ...OP001121 Operating Controls 2 6 OPERATIONAL CONTROLS AND PANELS Figure 3 20 19 18 17 21 22 24 23 1 2 3 5 4 26 16 27 14 13 12 11 10 9 8 6 15 25 7 FG015771 28 29 ...

Page 79: ...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 Switch 24 Shear Switch 25 Instrument P...

Page 80: ...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 81: ...ncy Stop Switch If the engine does not shut down when using the starter switch it can be stopped 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 1 Press the switch I untill the engine stops 2 When released the switch will return to its ...

Page 82: ...h time this power button is pressed the audio system is turned either ON or OFF If the audio system turns ON an indicator light above the button turns ON Press the up button to INCREASE volume Press the down button to DECREASE volume SCAN PWR FG000018 Figure 9 FG000019 PWR Figure 10 FG000020 Figure 11 FG000021 Figure 12 ...

Page 83: ...ition AUTOMATIC travel speed is selected The travel speed automatically changes between LOW or HIGH range depending on engine speed and travel motor loads 8 Light 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 ...

Page 84: ...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 85: ...Heater and Air Conditioner Control Panel on page 2 49 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 window is lifted the wiper motor will not operate Constant Speed Button Pressing the button turns ON the windshield wiper An indicator l...

Page 86: ...only the proper windshield washer fluid in the system NOTE Do not operate the windshield washer without any fluid If operate without any fluid the washer motor may be damaged Check level in washer tank and add fluid as required NOTE Using soapy water or synthetic detergent instead of window cleaning fluid may damage the wiper blade or painted surfaces Use standard window cleaning fluid SSK703 15 C...

Page 87: ...ing alarm will sound while swinging and traveling if equipped with a swing alarm device NOTE If machine is only equipped with a travel alarm device the alarm will not sound when swinging although the switch is in the II position 18 Overload Warning Switch Optional If unit is equipped with an overload warning device push this switch to activate it O In this position the overload warning device is t...

Page 88: ... 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 seat warmer is turned ON NOTE The starter switch must be ON with the engine running for the heater to operate 21 Horn But...

Page 89: ...ons For a machine equipped with shear press the two upper buttons on the top of the right hand work lever joystick to open or close the shear Left button is for closing crowd right button is for opening Dump NOTE These buttons work with the breaker boost shear selector switch See 9 Breaker Boost Shear Selector Switch on page 2 12 Figure 32 FG000382 WARNING Before using any attachment in a work app...

Page 90: ...e Safety Lever on page 3 13 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 C H E F C H FG013662 1 6 2 7 3 8 4 5 0 9 Figure 35 Figure 36 FG000038 FG000399 Figure 37 ...

Page 91: ...is switch is used to operate the auto greasing device manually O In this position the auto greasing device is operated for about six minutes every one hour If auto greasing device is needed to be operated manually please press this switch to I position I In this position the auto greasing device starts greasing and it lasts about six minutes This switch will be returned to O position automatically...

Page 92: ...MENT PANEL C H E F C H 1 6 2 7 3 8 4 5 0 9 5 1 2 14 16 13 15 19 17 21 3 4 18 22 20 23 6 CN7 CONNECTOR AND TERMINAL NO 12 6 5 11 4 10 14 8 7 15 16 2 1 8 7 3 9 12 5 4 3 2 1 10 11 9 6 13 CN6 AMP 040 28P 1 FG013521 CHECK 7 8 9 10 11 12 Figure 40 ...

Page 93: ...ck on page 2 42 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 27 5 Digital Clock 6 Hour Meter 7 Charge Warning 8 Engine Oil Pressure Warning 9 Engine Coolant Temperatur...

Page 94: ...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 95: ...en Allow the engine 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 29 for location of this warning symbol and others 4 Multifunction Gauge and Graphic Information Area See Multifunction Gauge and Graphic Information on page 2 27 This section will have a more in depth explanation of the display area 5 Digital C...

Page 96: ...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 97: ...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 98: ...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 51 HB4O2003 Figure 52 ...

Page 99: ...ump pressure BAR Rear pump pressure BAR NOTE See Figure 56 thru Figure 59 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 35 for the language selection and information display sequences Communic...

Page 100: ...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 101: ...merically 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 7 Water in Fuel Warning FRONT PUMP 320...

Page 102: ... Warning This symbol indicates when the pilot filter clogged 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 FG013703 FG013704 FG013705 2 kinds of warning display 4 kinds of warning display 7 kinds of warning display Figure 61 FG000056 Figure 62 FG000055 Figure 63 ...

Page 103: ...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 104: ... the load 7 Water In Fuel Warning This symbol indicates when the water is full in the fuel prefilter When this symbol appears drain the water from the fuel prefilter as soon as possible Figure 67 FG000253 WARNING If this warning appears on the screen and a warning buzzer sound reduce the load immediately If you continue to work the machine can be turned over or damage to hydraulic components and s...

Page 105: ...ivated 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 Selection on page 3 19 2 Economy Mode Selector Button Economy mode is used for light loading work when this mode selected it will reduce noise and fuel consumption with standard mode When the econo...

Page 106: ...ve 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 the engine speed dial and will remain at this speed despite control lever position until the engine speed dial is moved 4 Flow Control Button When the button is pushed you can control the hydraulic oil flow rate The flow control button is used to set the flow rate o...

Page 107: ...et the contents of the 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 E F C H FG013591 Figure 74 1 6 2 7 3 8 4 5 0 9 FG013712 1 2 3 4 5 Figure 75 FG000068 3 Figure 76 ...

Page 108: ... 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 hour of filter oil 5 Home Button Home button HOME is...

Page 109: ...nds are spent in 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 38 2 Set Clock on page 2...

Page 110: ...LECT button The set 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 ne...

Page 111: ...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 UP DOWN SELECT FG013566 SET CLOCK 02 30 30 2003 11 04 Figure 87 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 F...

Page 112: ...ero 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 returne...

Page 113: ...ode the default brightness and contrast is set to 50 the default backlight is set to 90 When it is night mode the default brightness is set to 50 the default contrast is set to 30 the default backlight is set to 10 Default value of camera display is 50 brightness 50 contrast 90 backlight The screen is return to the previous menu by pressing the ESC button The display is then saved 1 Language 4 Adj...

Page 114: ...ess 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 75 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 position After changing password be sure to use the changed password A three item menu will be d...

Page 115: ...ssword follow below procedure 1 Move the cursor to Change Password 2 Input desired 4 digits password using selection buttons at the first column Input the same password one more time at the second column 3 Select adoption lock or non adoption unlock at set password menu NOTE Keep in mind never to forget password NOTE Please contact a DOOSAN distributor if you forget your password UP DOWN SELECT FG...

Page 116: ...ow control button Figure 73 and Figure 100 is pressed at the normal display screen Figure 99 the flow control screen Figure 102 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 102 and Figure 103 Figure 99...

Page 117: ...s in engine rpm Escape A Press flow control button Figure 100 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 ESC CANCEL FG014885 APPLY FLOW CONTROL Figure 102 Breaker Flow Control Step Pump Flow Setting l min 1 130 2 160 3 190 4 220 5 250 6 280 7 310 8 340 9 350 10 350...

Page 118: ...PERATION SELECTION DISPLAY In the monitor you can see the application that is currently selected Power Mode Selection Standard Mode Selection Economy Mode Selection Figure 105 PWR FG013720 Figure 106 STD FG013721 Figure 107 ECO FG013722 ...

Page 119: ...1121 2 47 Operating Controls Auto Idle Selection Power Boost Selection Breaker Selection Shear Selection Figure 108 PWR FG013723 AUTO Figure 109 PWR FG013724 Figure 110 PWR FG013725 Figure 111 PWR FG013726 ...

Page 120: ...this button 1 Figure 113 to turn camera mode ON or OFF When the camera mode button is pushed to the ON position the camera window appears on the screen When the camera mode button is pushed again it is turned OFF and the camera mode is deactivated and return to the default screen Figure 112 PWR FG013728 Figure 113 1 6 2 7 3 8 4 5 0 9 FG013836 1 ...

Page 121: ...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 114 FG013837 ...

Page 122: ... 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 115 Reference Number Description 1 Automatic Temperature Control Button 2 Off Button 3...

Page 123: ...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 117 Figure 118 TEMP FG000090 SEL FG000094 Figure 119 ...

Page 124: ... 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 120 FG000099 Figure 121 FG000097 Figure 122 FG000100 Figure 1...

Page 125: ...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 126: ...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 127: ... 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 131 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 AST DIR FG000109 Figure 132 ...

Page 128: ...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 129: ...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 4 77 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 HAOB100L A Figure 136 WARNING When changing the fusible li...

Page 130: ...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 138 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 131: ...rd 5 Armrest Angle Adjustment The angle of each armrest can be adjusted by turning a dial 5 Figure 139 on bottom of armrest When adjusting the angle manually raise the armrest before turning the dial 6 Lumbar Support Adjustment A lumbar support is located in the seat back Turn the dial 6 Figure 139 counterclockwise to increase the force of the lumbar support 7 Headrest The headrest 7 Figure 139 ca...

Page 132: ...tion 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 chance and severity of injury in case of an accident Never fasten a seat belt across the abdomen Under no circumstances should the operator be standing in the cabin when operating the excavator Do not adjust the seat position while the vehicle is...

Page 133: ...he lower part of the seat can be turned to adjust the elevation height of each control stand It can be used to adjust the height of the control joystick 12 Air Suspension Seat Optional The operator seat is also available with air suspension for even better comfort The switch 12 Figure 143 in the middle of the seat can be used to adjust the air cushion If the switch is pressed the seat become harde...

Page 134: ...it with a soft fabric towel Opening the Ceiling Cover 1 Lower bucket to ground 2 Set safety lever Figure 145 on LOCK 3 Pull the lock 1 Figure 146 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 145 on LOCK 3 Pull down cover with the handle Figure 146 so that the lock 1 can be locked in the bracket in the ceili...

Page 135: ... 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 136: ...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 150 from cabin in direction of the arrow 2 Set bottom window in rubber holders 2 Figure 151 behind operator s seat Secure window with left and right knobs 3 with push button 4 1...

Page 137: ...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 153 down The latch lever is to the left of the operator s seat 1 FG000196 Figure 152 2 FG000673 Figure 153 ...

Page 138: ...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 155 on the right side of operator s seat ASHTRAY An ashtray 1 Figure 156 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 154 3 FG000675 Figu...

Page 139: ...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 158 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 159 HANGER A hanger 1 Figure 160 is located on the upper left side of the operator s...

Page 140: ... be reduced by tightening knob 1 Figure 162 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 161 1 FG0...

Page 141: ...n door until locking device 1 Figure 165 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 166 in the slot 2 until it locks in notch 3 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 FG016076 2 1 Figure 164 FG016077 1 Figure 165 FG016078 3 1 ...

Page 142: ...OP001121 Operating Controls 2 70 ...

Page 143: ...e 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 for ...

Page 144: ... 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 145: ...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 146: ...t appear 5 Turn starter 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 FG013717 ENTER PASS...

Page 147: ...rning 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 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 ...

Page 148: ... OFF 5 After the preheat completion immediately turn starter switch to START position Figure 10 Engine should start in approximately five seconds HAOB34L Figure 7 WARNING DO NOT USE STARTING FLUIDS The preheat system could cause the starting fluid to explode Starting fluids should never be used FG000084 O I Figure 8 PWR FG013732 1 Figure 9 FG000085 O I Figure 10 WARNING If the engine does not star...

Page 149: ...rks 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 start vehicles on dry ground or concrete Do not jump start the machine on a steel floor because the floor is always grounded 6 When starting from another mac...

Page 150: ...achine 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 Disconnect ...

Page 151: ...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 152: ...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 153: ...to be slow continue to operate but use extreme caution because the machine function may be erratic 7 Check for clearance and fully raise the front attachment Slowly swing clockwise 3 revolutions Slowly swing counterclockwise 3 revolutions 8 Travel forward and reverse at low speed for two revolutions of the drive sprocket HAOB550L Figure 20 ...

Page 154: ...xcavator on level and firm ground 2 Lower front end attachment to ground and make sure all operating controls are in NEUTRAL 3 Set safety lever on LOCK position Figure 22 4 Set engine speed control dial to LOW IDLE Figure 23 Allow engine to idle for three five minutes 5 Shut down engine by turning key to O OFF position Figure 24 6 Remove key from starter switch Figure 21 FG015775 FG001091 Unlock L...

Page 155: ...moved NOTE Lower bucket front attachment to ground Place all control levers in NEUTRAL and shut down engine before using the safety lever 2 Set safety lever Figure 25 on RELEASE UNLOCK position by pulling it up before starting work 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...

Page 156: ...e sure that you know in which direction the machine is pointing Look at the end of the track assemblies If the drive motors are visible 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 person...

Page 157: ... one track forward or 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 ...

Page 158: ... 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 Figure 32 FG015776 40 50 cm Figure 33 FG0...

Page 159: ...r s door on a slope Make sure door is latched FG015846 Figure 34 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 slope...

Page 160: ... Water on page 3 29 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 FG000376 Figure 37 CAUTION When using the boom and arm ...

Page 161: ...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 symbol indicates on the screen Deactivate the power mode by pressing it a second time When the power mode is turned OFF the symbol of standard mode indicates on the screen and the power mode returns to the standard mode ...

Page 162: ...standard mode Auto Idle Mode 1 The system will automatically reduce engine speed to idle speed approximately four seconds after all of the control levers are in the 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 symbol is turne...

Page 163: ...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 164: ...n 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 faster than the amount of oil being supplied Right hand Work Lever Joystick Figure 44 and Figure 47 5 Boom down 6 Boom up 7 Bucket crowd 8 Bucket dump NOTE ...

Page 165: ...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 49 FG000381 1 5 2 6 4 3 8 7 Figure 48 WARNING Check surrounding area before swinging When operating a lever while in auto idle do it carefully bec...

Page 166: ...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 167: ... 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 168: ...out force See Figure 57 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 58 to the rear See Figure 58 10 Do not excavate underneath the machine See Figure 59 Figure 56 FG015784 Figure 57 FG015785 Figure 58 FG015786 Figure 59 FG01575...

Page 169: ... that there is adequate overhead clearance and that there is adequate ventilation See Figure 61 13 Do not use the bucket as a hammer or ramming device This is dangerous and causes damage to the front attachment See Figure 62 14 Do not dig with the excavator tracks raised This can result in structural and mechanical failures Figure 60 FG015758 Figure 61 FG015787 Figure 62 FG015788 Figure 63 FG01578...

Page 170: ...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 64 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 171: ...f 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 Figure 65 FG015790 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 damage and or engine ECU damag...

Page 172: ... operation lever unintentionally it may create a serious accident Before leaving operator s seat set safety lever on LOCK position 120 FG015855 Figure 67 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 67 Figure 68 FG015775 HAOB290L Figure 69 FG001091 Unlock Lock Figure 70 ...

Page 173: ...When towing excavator use a wire rope or chain capable of handling the load Attach chain or wire rope to track frame as shown in Figure 71 Insert protective material such as thick cloths between track frame and wire rope to prevent the wire rope from being damage IMPORTANT Use shackle hook on track frame to only haul objects that weigh less than 10 metric tons 11 0 U S Tons Never use it to haul ob...

Page 174: ...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 175: ...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 73 Leave over 100 mm 4 in of clearance between rod end of cylinder and cylinder head This will help prevent damage to cylinders during breaker operation 5 Do not use the breaker if the hydraulic hoses vibrate excessively Se...

Page 176: ...See Figure 76 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 77 9 Do not curl the breaker tool tip into the arm or boom when traveling or parking the excavator See Figure 78 HAOB970L Figure 75 FG016127 Figure 76 HAOB990L Figure 77 WARNING Operating a bre...

Page 177: ... 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 relief v...

Page 178: ...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 179: ... 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 82 FG013831 Normal Display Flow Control Display FLOW CONTROL ESC CANCEL APPLY C H E F C H 1 6 2 7 3 8 4 5 0 9 Flow Control Step 1 Pump Flow Setting l min 2 Pump Flow Setting l min 0 52 1 130 1 Pump Flow 300 l min 79 U S gpm 2 160 3 190 4 220 5 251 6 281 7 311 8...

Page 180: ...ke sure that stopper Figure 85 is in BREAKER position NOTE When stopper is in BREAKER position pedal valve can be only moved in one direction 3 With the stopper in BREAKER position pedal can only be pressed in direction 1 Figure 83 When pedal is in its center at rest position valve is in NEUTRAL and hydraulic oil flow is stopped Stopper Positions The stopper has three positions Shear Breaker Locke...

Page 181: ...sitioned 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 contr...

Page 182: ... 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 against tip over One method is to position the boom at 90 over the side ...

Page 183: ...ty precautions required in each case The following factors must be considered before attempting to pick and carry a load Align the boom with the forward direction of machine travel Maintain this boom position when turning the machine Turn only when necessary at the slowest speed and at a wide turning radius 1 Use the shortest lifting radius distance possible 2 Keep the load as close to the ground ...

Page 184: ...s 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 machine according to Periodic Service Table and Chart Section 4 in this manual or lubrication chart on machine 7 Star...

Page 185: ...rge at a higher rate if left standing for long periods at high temperatures If machine is to stand for several days remove batteries and store in a cool place 3 Service fuel system as directed in Engine Fuel System Section 5 of this manual Check for water content before filling fuel tank High temperatures and cooling off cause condensation in storage drums 4 Lubricate as specified in Periodic Serv...

Page 186: ...ine under cover or protect with tarpaulin to keep dust and sand from damaging unit Operation in Rainy or Humid Conditions Operation under rainy conditions is similar to that as in extreme heat procedures listed previously 1 Keep all exposed surfaces coated with preservative lubricating oil Pay particular attention to damaged or unpainted surfaces Cover all paint cracks and chip marks as soon as po...

Page 187: ...outlined in extreme cold Before operating at high altitudes engine fuel and air mixture may have to be adjusted according to appropriate engine manual 1 Check engine operating temperature for evidence of overheating The pressure cap on radiator must make a perfect seal to maintain coolant pressure in the system ...

Page 188: ...OP001122 Operation 3 46 ...

Page 189: ...ges list the service checks and their required intervals The service cycles may need to be shortened depending on the working conditions Extremely hot or dusty conditions will require more frequent service Operational hours are determined by the amount of time accumulated on the engine hour meter on the control console in the cabin NOTE Besides the normal hour meter the multifunction gauge can be ...

Page 190: ...is also stamped on the product identification plate Figure 4 on outside of the cabin on right NOTE Please make note of these numbers and their locations These will be required whenever warranty or service work is requested Keep this number on file incase the machine is stolen Figure 3 FG001447 FG012987 Doosan Infracore Co Ltd 7 11 Hwasu dong Dong gu Incheon Korea Figure 4 ...

Page 191: ...arranty service work is requested Safety 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 o...

Page 192: ...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 Figure 6 FG015775 FG001091 Unlock Lock Figure 7 HAOB290L Figure 8 ...

Page 193: ...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 194: ... specification below Using other products may damage the equipment Reservoir Kind of Fluid Ambient Temperature 22 4 14 32 50 68 86 104 122 F 30 20 10 0 10 20 30 40 50 C Engine Oil 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...

Page 195: ...tute ACEA Association des Constructeurs Europens d Automobiles ASTM American Society of Testing and Material ISO International Standardization Organization NLGI National Lubricating Grease Institute SAE Society of Automotive Engineers CAUTION Do not mix oils from different manufacturers DOOSAN does not endorse specific brands but does suggest that owners select quality oils whose suppliers provide...

Page 196: ...l Cooling System 69 liters 18 2 U S gal Fuel Tank 900 liters 237 8 U S gal Hydraulic Oil Tank Level 350 liters 92 5 U S gal System 790 liters 208 7 U S gal Travel Reduction Device Each 20 liters 5 3 U S gal Swing Device Each 6 liters 1 6 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 197: ...OP001123 4 9 Inspection Maintenance and Adjustment ...

Page 198: ...1123 Inspection Maintenance and Adjustment 4 10 Description of Lubrication and Service Chart FG015856 50h 500h 250h 2000h 1000h 10h AUTO 18 16 12 22 17 10 21 5 3 4 6 1 1 8 20 14 15 9 19 13 11 7 2 Figure 11 ...

Page 199: ... 2 1 F 16 Pilot Filter Element 1 F 17 Hydraulic Oil Suction Strainer Strainer 1 C 18 Engine Oil Filter Cartridge 2 F 19 Fuel Filter Cartridge 2 20 Air Cleaner Outer Element 1 C Air Cleaner Inner Element 1 21 Air Conditioner Filter Outer Cartridge 1 C Air Conditioner Filter Inner Cartridge 1 C 22 Air Breather Filter Cartridge 1 V Maintenance and Refill C Cleaning F First Time Exchange Only F100 Eve...

Page 200: ...ck 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 24 50 Hour Weekly Service Perform All Daily Service Checks 4 25 Grease Arm and Bucket Joint Pins 4 25 Grease Swing Bearing Only Manual Greasing 4 26 Drain Water and Sediment from Fuel Tank 4 27 Check Engine Fan Belt for Cracks Wear and ...

Page 201: ...Reduction Device 4 43 Replace Hydraulic Oil Return Filter Drain Return Filter 4 44 Change Pilot Filter 4 45 Change Oil in Travel Reduction Device One on Each Side of Unit 4 46 Change Air Breather Filter 4 46 Change Air Conditioning Outer Filter 4 47 Change Fuel Cap Filter 4 48 Check Air Conditioner Refrigerant 4 50 Check and Adjust Engine 4 50 2 000 Hour Yearly Service Perform All Daily 50 250 500...

Page 202: ... Figure 13 and wipe the oil off with a clean cloth 3 Insert dipstick fully in the oil gauge tube then take it out again 4 Engine oil level must be between HIGH and LOW marks on dipstick NOTE If oil is above HIGH mark on dipstick some must be drained to return oil to proper level 5 Add oil through engine oil fill cap 2 Figure 13 if the oil level is below the LOW mark FG000500 Figure 12 WARNING Do n...

Page 203: ...surized air to vent C Remove the upper cover of the hydraulic tank and add oil ARO1760L Figure 15 WARNING The hydraulic oil will be hot after normal machine operation Allow the system to cool before attempting to service any of the hydraulic components The hydraulic tank is pressurized Lift the breather cap slowly to allow the pressurized air to vent After the pressure has been released it is safe...

Page 204: ...t the bottom of the tank into a suitable container using a hose at the point plug NOTE Dispose of drained fluids according to local regulations 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 Figure ...

Page 205: ...the optional battery operated fuel fill pump The pump assembly is in the hydraulic pump compartment Put the suction hose of the pump into the fuel resupply tank Turn the switch in the pump compartment ON and the fuel will be pumped into the excavator fuel tank NOTE See Fuel Transfer Pump Optional on page 4 84 for further information 5 Do not overfill the tank 6 Securely tighten cap after fueling N...

Page 206: ...t panel comes ON drain the collected water in fuel prefilter 1 A fuel prefilter is inside the left rear side access door 2 Open the access door on 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 D...

Page 207: ...rk on dipstick some 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 release the drain plug Figure 27 Drain the excessive oil into a suitable container NOTE Dispose of drained fluids according to local regulations Figure 25 FG015801 2 2 1 1 WARNING The gear oil is very ...

Page 208: ...r to clean the core IMPORTANT If running excavator 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 FG016102 Figure 28 WARNING There should be no person in front of the fan in order to keep persons from being injured by scatterd material WARNING If using compressed air or water to...

Page 209: ... recovery tank The normal cold engine fluid level should be between FULL and LOW marks on tank 4 If the coolant is below the LOW mark add coolant 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 wea...

Page 210: ...ers buckets refer to their specific instructions Inspect Engine Fan Blade NOTE Manually rotate the crankshaft by using a wrench on the accessory drive pulley nut 1 An inspection of the cooling fan is required daily Check for cracks loose bolts bent or loose blades and for contact between the blade tips and the fan shroud Check the fan to make sure it is securely mounted Tighten the bolts if necess...

Page 211: ...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 33 CAUTION Hot engine components can cause burns A...

Page 212: ... Listen for Any Abnormal Sounds Check Operation of All Controls 1 With the engine at rated speed operate all of 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 ma...

Page 213: ...f Auto Greasing Device a 10 hour daily basis Position machine as shown below and lower the front attachment to the ground at the engine ON Press the grease fitting and inject grease with the grease gun on the marked point Please check the marked point of greasig After injection clean off the old grease that has been purged Figure 35 Reference Number Description A Arm Link Joint Pin 1 Point B Link ...

Page 214: ...cket cylinder rod pin 1 point Grease Swing Bearing Only Manual Greasing 1 Position the machine on firm level ground Lower the front attachment to the ground and shut down engine 2 There are three grease fittings for the swing bearing Do not over lubricate Purge old grease with new Remove all purged grease FG016128 A C Figure 36 FG016129 B D B E Figure 37 FG016197 Figure 38 ...

Page 215: ...nspect after first 50 hours of operation and every 250 hours thereafter For details See Check Engine Fan Belt Tension on page 4 30 Change Engine Oil and Filter After First 50 Hours 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 35 Inspect the Track Assemblies for Proper Tension and Loose W...

Page 216: ...ing Device a 10 hour daily basis Position machine as shown below and lower the front attachment to the ground at the engine ON Press the grease fitting and inject grease with the grease gun on the marked point Please check the marked point of greasig After injection clean off the old grease that has been purged Figure 40 Reference Number Description A Boom Cylinder Head Pin 2 Points B Boom Foot Pi...

Page 217: ...in 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 F Arm cylinder rod pin 1 point G Bucket cylinder head pin 1 point FG016176 A A Figure 41 FG016130 C D C B B Figure 42 FG016131 E G F E Figure 43 ...

Page 218: ... belt should flex approximately 6 8 mm 0 24 0 31 in See Figure 44 To adjust the belt loosen the alternator adjustment plate bolts adjust the belt tension and retighten the bolts Alternator Alternator Idle Pulley Compressor Water Pump Water Pump 6 8 mm 0 24 0 31 in 10 kg 22 Ib CRS Pulley CRS Pulley FG016161 Figure 44 IMPORTANT A loose fan belt can cause engine overheating poor charging and or prema...

Page 219: ...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 Che...

Page 220: ...ic oil tank breather cap to release pressure 3 Locate breaker filter assembly Figure 47 4 Position a container under the filter assembly Remove the drain plug and completely drain the assembly 5 Using a 30 mm spanner unscrew filter housing from filter bottom 6 Remove O ring from filter head 7 Replace filter 8 Apply a small amount of oil around the entire O ring and install the filter housing on th...

Page 221: ... or rebuild and every 1 000 hours thereafter See page 4 46 Replace Hydraulic Oil Return Filter After First 250 Hours NOTE Replace hydraulic oil return filter after first 250 hours of operation or rebuild then every 1 000 hours thereafter See page 4 44 Change Pilot Filter After First 250 Hours NOTE Change pilot filter after first 250 hours and every 1000 hours thereafter See page 4 45 Inspect Pins ...

Page 222: ...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 223: ...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 52 Refer to the Lubrication Table of this manual for the recommended oil for the operating conditions NOTE See Fluid Capacities on page 4 8 for capacity 5 Start engine Run engine for five minutes at LOW IDLE and ...

Page 224: ... operator being seated in the operator s seat facing the front 1 Open the door in the left front of the machine then remove the cover 1 Figure 53 by loosening the four wing bolts 2 Open the cover by turning the knob 1 Figure 54 in the rear of the cabin 3 Remove filter Figure 55 and inspect for any damage 4 Use compressed air to clean filter If filter is still dirty then change to new one 5 Reassem...

Page 225: ... 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 56 FG000422 WARNING All service and inspection of air conditioning system should be performed with the starter switch in the O OFF position WARNING If using compressed air to clean the element make sure that proper eye protection is worn IMPORTAN...

Page 226: ...ent outwards 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 FG016114 Figure 57 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 pre...

Page 227: ...ced NOTE Replace outer filter after cleaning 5 times or every 2 000 hours 1 year of service 2 Remove and clean rubber evacuator valve 1 Figure 60 from bottom of air cleaner housing cover 2 Inspect seal lips for wear or damage Replace valve if necessary NOTE Install evacuator valve with lips parallel to the cover 3 Remove the access cover 2 Figure 61 by loosening the latches 4 Remove the outer filt...

Page 228: ...thinner parts are found on the element after cleaning it replace the filter 7 Clean the inside of the air cleaner body and the inside of the air cleaner cover Do not use 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 ou...

Page 229: ...to local regulations 3 Remove the bowl using supplied tool 4 Remove the cartridge 5 Coat surface of packing 2 Figure 66 with fuel on new cartridge 1 6 Tighten the cartridge by hand until the packing comes into contact with the surface of the filter housing head 7 When it reach the surface tighten the cartridge about 3 4 of a turn more 8 Coat surface of seal 3 Figure 66 with fuel and tighten the bo...

Page 230: ... 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 Loosen plug 1 Figure 69 on the fuel prefilter head 3 Pump the hand operated...

Page 231: ...machine on firm level ground Lower the front attachment to the ground and shut down engine 2 Remove air vent plug 1 Figure 70 from swing reduction device at manual gerasing ports 3 Press grease fitting and inject grease with the grease gun on the marked point 2 Figure 71 4 Install air vent plug 1 Figure 70 in swing reduction device Figure 70 FG001564 1 1 Figure 71 FG016198 2 2 ...

Page 232: ...ed of according to local regulations 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 73 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 72 FG013832 FG016117 2 3 1 Figure 73 WARNING The hydraulic oil will be h...

Page 233: ...er assembly See Figure 76 4 Unscrew canister 5 Figure 77 and remove O ring 3 and filter cartridge 4 NOTE The canister will be filled with oil Use caution when removing this assembly 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 77 NOTE Used filter should always be disposed of according...

Page 234: ...vel 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 Change Air Breather Filter 1 Position the machine on firm level ground Lower the front attachment to the ground and shut down engine 2 Lift the breather cap 2 Figure 79 slightly to release the internal pressure 3 Unscrew the bolt 1 Figure 79 and take off the br...

Page 235: ...ed 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 front of the machine then remove four wing bolts and washers and access cover 1 Figure 80 2 Open the cover by unscrewing the knob 1 Figure 81 in the rear of the cabin 3 Remove filter Figure 82 and replace with new one ...

Page 236: ...ate bolt to CCW direction to loosen 2 After disengaging it as shown on Figure 85 carefully lay it on floor 3 After disengaging disengage rubber as shown on Figure 86 FG015720 Figure 83 WARNING External shock or damages to fuel cap may lead to permanent damage to filter FG015684 Figure 84 FG015685 Figure 85 FG015686 Figure 86 ...

Page 237: ...e and Adjustment 4 After disengaging as shown on Figure 86 you may now exchange it to a new filter as shown on Figure 87 5 After exchanging to a new filter you may now assemble back in reverse order FG015687 Figure 87 FG015688 Figure 88 ...

Page 238: ...SAN dealer Engine dealer for checking and adjusting the following items Engine Compression Pressure Injection Pressure Injection Timing FG016137 Figure 89 WARNING Mixing of tobacco smoke and freon is deadly Do not smoke while servicing or recharging air conditioning system CAUTION Overfilling refrigerant may cause dangerous high pressure and poor cooling action and low refrigerant level may cause ...

Page 239: ...et a container under excavator 2 Release the drain plug 3 Figure 91 and drain the swing reduction device oil into a container NOTE Dispose of drained fluids according to local regulations 3 After draining oil tighten the drain plug 4 Remove breather fill cap 2 Figure 90 and add oil to H mark on dipstick 1 FG015801 2 2 1 1 Figure 90 WARNING The gear oil is very hot after the machine has been operat...

Page 240: ...age Replace valve if necessary Install evacuator valve with lips parallel to the cover 3 Remove outer filter 3 Figure 93 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 94 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 ...

Page 241: ...unning 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 not remove the radiator cap unless it is required Observe the coolant level in the coolant recovery tank CAUTION Do not mix ethylene glycol and propylene glycol when changing the antifreeze solution Flushing should be performed ...

Page 242: ...valve 2 Figure 97 Reconnect heater hoses with clamps 5 and 6 Figure 99 10 Do not install EGR plugs 3 and 4 Figure 98 11 To prevent air from entering cooling system slowly fill system with coolant Use proper antifreeze mixture for ambient temperature NOTE Refer to coolant concentration table See Antifreeze Concentration Tables on page 4 83 12 When system is filled with coolant to EGR plug holes 3 a...

Page 243: ...elease pressurized air from hydraulic tank by lifting breather cap 1 Figure 104 Figure 100 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 Lift the breather cap to allow the pressurized air to vent After the pressure has been released it is safe to r...

Page 244: ...on strainer 5 Figure 104 on boss portion of suction pipe 6 NOTE Measurement A is 787 mm 30 98 in 10 Fill the hydraulic oil tank Check level using sight gauge on side of tank 11 Place spring 3 Figure 104 on rod 4 and assemble cover 2 12 After replacing and cleaning the hydraulic oil filter and strainer vent the system See Venting and Priming Hydraulic System on page 4 89 13 Check level of hydraulic...

Page 245: ...hecks 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 ...

Page 246: ...arts 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 ECU to engine CP pump Fuel hose Tank to CP pump Heater hose Heater to engine Heater hose Heater to radia...

Page 247: ...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 relat...

Page 248: ... 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 38 Check Magnetic Clutch Check the magnetic clutch for dirt and interference Push the A C switch in order to energize magnetic clutch and check the magnetic clutch Check Belt Tens...

Page 249: ...k 20 6 30 55 539 398 5 Tightening bolt for fuel tank 20 6 30 55 539 398 6 Tightening bolt for pump 12 4 8 19 11 9 108 88 80 65 7 Tightening bolt for control valve 20 4 30 55 539 398 8 Tightening bolt for swing reduction device 24 24 36 95 932 687 9 Tightening bolt for swing motor 16 4 14 27 265 195 10 Tightening bolt for battery 10 2 17 5 49 36 11 Joint bolt with cabin mounting rubber and frame 10...

Page 250: ...92 289 19 Fixing bolt for track frame and side frame 36 40 55 288 2824 2083 20 Fixing bolt for fan motor 16 12 2 1 24 19 24 11 265 108 195 80 21 Fixing bolt for fan pump 14 2 12 17 167 123 22 Breaker Filter Optional PF1 2 2 10 27 265 195 NO POINT TO BE INSPECTED BOLT DIA mm QTY BOLT HEAD SIZE TORQUE kg m Nm ft lb ...

Page 251: ...e 10 5 kg m 103 Nm 123 ft lb 2 Fan side Tool 22 mm Torque 17 kg m 167 Nm 123 ft lb 2 Joint bolt and nut between engine mounting bracket and frame 1 Pump side Tool 36 mm Torque 91 kg m 892 Nm 658 ft lb 2 Fan side Tool 36 mm Torque 91 kg m 892 Nm 658 ft lb FG016173 Figure 105 FG016083 Figure 106 FG016084 Figure 107 FG016085 Figure 108 ...

Page 252: ...ulic oil tank Tool 30 mm Torque 55 kg m 539 Nm 398 ft lb 5 Tightening bolt for fuel tank Tool 30 mm Torque 55 kg m 539 Nm 398 ft lb 6 Tightening bolt for pump 1 Main pump Tool 19 mm Torque 11 kg m 108 Nm 80 ft lb 2 Pump cover Tool 19 mm Torque 9 kg m 88 Nm 65 ft lb FG016086 Figure 109 FG016087 Figure 110 Figure 111 FG016088 FG016089 1 2 Figure 112 ...

Page 253: ...98 ft lb 8 Tightening bolt for swing reduction device Tool 36 mm Torque 95 kg m 932 Nm 687 ft lb 9 Tightening bolt for swing motor Tool 14 mm Torque 27 kg m 265 Nm 195 ft lb 10 Tightening bolt for battery Tool 17 mm Torque 5 kg m 49 Nm 36 ft lb FG016090 Figure 113 FG016091 Figure 114 FG016092 Figure 115 FG001592 Figure 116 ...

Page 254: ...lt with cabin mounting rubber and cabin Tool 24 mm Torque 21 kg m 206 Nm 152 ft lb 12 Joint bolt with swing bearing and upper frame Tool 46 mm Torque 176 kg m 1 726 Nm 1 273 ft lb Joint bolt with swing bearing and bottom frame Tool 46 mm Torque 182 kg m 1 785 Nm 1 316 ft lb FG000454 Figure 117 FG000455 Figure 118 FG016093 Figure 119 FG001594 Figure 120 ...

Page 255: ... 883 Nm 651 ft lb Tightening bolt for sprocket Tool 36 mm Torque 90 kg m 883 Nm 651 ft lb 14 Tightening bolt for upper roller 1 Fan side Tool 30 mm Torque 53 kg m 520 Nm 383 ft lb 2 Flange side Tool 30 mm Torque 53 kg m 520 Nm 383 ft lb FG016094 Figure 121 FG016095 Figure 122 FG016096 Figure 123 FG016097 Figure 124 ...

Page 256: ...90 kg m 883 Nm 651 ft lb 17 Bolt for track shoes Tighten the bolts in the order as shown in the Figure 127 1 4 Tool 36 mm Torque 191 kg m 1 874 Nm 1 381 ft lb 18 Fixing bolt for front pin 1 Arm end side Tool 24 mm 1 Torque 27 kg m 265 Nm 195 ft lb Tool 30 mm 2 Torque 55 kg m 392 Nm 152 ft lb FG016098 Figure 125 FG016099 Figure 126 FG016171 2 4 3 1 Figure 127 FG016147 1 1 2 Figure 128 ...

Page 257: ...ool 24 mm 1 Torque 27 kg m 265 Nm 195 ft lb Tool 30 mm 2 Torque 55 kg m 539 Nm 398 ft lb 3 Bucket side Tool 24 mm 1 Torque 27 kg m 265 Nm 195 ft lb Tool 30 mm 2 Torque 55 kg m 539 Nm 398 ft lb FG016148 2 1 Figure 129 FG016151 1 2 Figure 130 FG016149 1 2 Figure 131 FG016150 2 2 Figure 132 ...

Page 258: ...or track frame and side frame Tool 55 mm Torque 288 kg m 2 824 Nm 2 083 ft lb 20 Fixing bolt for fan motor Tool 24 mm 1 Torque 27 kg m 265 Nm 195 ft lb Tool 19 mm 2 Torque 11 kg m 108 Nm 80 ft lb FG016107 Figure 133 FG016172 1 2 2 1 2 2 2 Radiator Oil Cooler Figure 134 ...

Page 259: ...ction Maintenance and Adjustment 21 Fixing bolt for fan pump Tool 12 mm Torque 17 kg m 167 Nm 123 ft lb 22 Fixing breaker filter Optional Tool 10 mm Torque 27 kg m 265 Nm 195 ft lb FG016153 Figure 135 FG016175 Figure 136 ...

Page 260: ...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 261: ...ing and temporarily install new O ring 1 Figure 141 onto bucket boss 2 Make sure that O ring groove on both bucket link 4 and boss have been cleaned 4 Realign arm or link with bucket pin hole and insert bucket pin 3 Figure 140 5 Roll new O ring 1 Figure 142 into O ring groove FG000502 Figure 139 WARNING Due to possibility of flying metal objects always wear safety helmet protective gloves and eye ...

Page 262: ...t Total clearance should be 1 mm 0 04 in between side face of boss and inside edge of ear bushing Y Figure 143 Too tight a fit less than 1 mm 0 04 in can cause excessive wear while too much clearance may produce excessive noise and potentially hazardous slack control 3 Recheck end play by forcing bucket towards opposite side and repeating clearance measurements 4 If an adjustment is required remov...

Page 263: ...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 264: ...ed BLACK Insufficient charged TRANSPARENT Replace battery Check the Battery Terminals Be certain that the battery is held securely in its compartment Clean the battery terminals and the battery cable connectors A solution of baking soda and water will neutralize acid on the battery surface terminals and cable connectors Petroleum jelly or grease can be applied to the connectors to help prevent cor...

Page 265: ...nents or fire can result Fuse Boxes There are two fuse boxes Figure 147 on the left side of the heater box The fuses prevent electrical devices from overloading or shorting A decal attached to the inside of the fuse box s cover indicates the function and amperage of each fuse Spare fuses are mounted on the inside of fuse box s cover One each of a 10A 15A 20A and 30A Change a fuse if the element se...

Page 266: ...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 15A 11 Fuel Heater 20A 12 Seat Heater Optional 15A 12 Instrument Panel Pressure Senso...

Page 267: ...tive concentration of the system Check the coolant every 500 hours Engine overheating is often caused by bent or clogged radiator fins The spaces between the fins can be cleaned by use of air or water under pressure When straightening bent fins use care not to damage the tubes or break the bond between the fins and the tubes CAUTION Maintaining the proper anticorrosive additive levels in antifreez...

Page 268: ... 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 change color NOTE Measuring time should not be more than 75 seconds If it is over this time limit the color will be changed and an inaccurate reading will result 4 Compare the color of the test strip with the c...

Page 269: ... Be sure that engine reaches operating temperature to ensure a thorough mix Shut down engine and retest antifreeze NOTE When making adjustment drain 1 liter 1 U S quart of coolant from the radiator Add 30 cc 1 fl oz at a time to the drained fluid Keep track of how many cc s fl oz s were added to the 1 liter 1 U S quart to obtain a proper reading Then multiply that number times the total system cap...

Page 270: ...llow There are even some that come in a blue green color The blue green color makes it very difficult to tell the difference of what type of antifreeze is in a cooling system The colors are only a dye added to the clear antifreeze Do not rely on color Keep careful machine records of what brand and type of antifreeze is used in the unit If you are unsure of what type of antifreeze is in the system ...

Page 271: ...thylene Glycol Doosan Genuine Antifreeze Solution for all seasons 2 000 Hour Yearly Ambient Temperature Cooling Water Antifreeze 10 C 14 F 80 20 15 C 5 F 73 27 20 C 4 F 67 33 25 C 13 F 60 40 30 C 22 F 56 44 40 C 40 F 50 50 Propylene Glycol Doosan Genuine Antifreeze Solution for all seasons 2 000 Hour Yearly Ambient Temperature Cooling Water Antifreeze 10 C 14 F 78 22 15 C 5 F 71 29 20 C 4 F 65 35 ...

Page 272: ...el contaminated with water or high humidity Moisture in pump mechanism can cause rust and can create pump failure Always operate pump using strainer installed on inlet hose This will prevent any foreign materials from being introduced into pump Always maintain pump and all of its components in a clean condition If dirt or other foreign materials enter pump it can become lodged between the rotor an...

Page 273: ...ose 3 Figure 149 into refueling tank 2 Turn fuel pump ON press Figure 150 inside of battery box on front side NOTE Transfer pump rate of flow is approximately 100 liters minute 26 4 U S gpm Use extra care not to overfill fuel tank so that fuel does not over flow 3 Once fuel transfer is completed automatically OFF position to stop pump 4 Lift inlet hose 3 Figure 149 from fueling source and turn swi...

Page 274: ... 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 275: ...rance can cause excessive component wear The recommended adjustment can also be too tight causing accelerated stress and wear if ground conditions are wet marshy or muddy or if the ground is hard and full of rocks or gravel 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 pers...

Page 276: ...ight the idler wheel and adjusting cylinder can be retracted by bleeding off grease through hole in valve 3 Figure 154 by loosening valve slowly NOTE After track tension is adjusted by loosening valve be sure to tighten valve 3 Figure 154 with 27 kg m 265 Nm 195 ft lb WARNING The track adjusting mechanism is under very high pressure NEVER release pressure too suddenly The grease cylinder valve sho...

Page 277: ...m the connection 9 When hydraulic oil begins to leak tighten hose connector 10 Shut down engine turn starter switch ON and slowly lower the boom until the bucket pin touches the ground This will increase the air pressure in the hydraulic tank 11 Slowly loosen air bleeding plug 4 until hydraulic oil leaks out 12 When hydraulic oil begins to leak then tighten plug 4 Hydraulic Cylinders 1 Run engine ...

Page 278: ...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 279: ...ct for damaged loose or missing parts Repaint necessary area to prevent oxidation Wash and clean all parts of machine Store the machine indoor stable place If stored outside cover with a waterproof tarpaulin Perform lubrication procedures on all grease points Apply a coating of light oil to the exposed plated metal surfaces such as hydraulic cylinder rods etc and to all the control linkage and con...

Page 280: ...tate track to prevent track seizing Every 90 days use a hydrometer to measure the protection of the coolant Refer to the antifreeze coolant protection chart to determine protection of the cooling system Add coolant as required After Storage When operating the work equipment remove all grease from the hydraulic cylinder rods Add grease and oil at all lubrication points Adjust fan and alternator bel...

Page 281: ...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 282: ...OP001123 Inspection Maintenance and Adjustment 4 94 ...

Page 283: ...ed removable counterweight may also have to be removed NOTE Obey all local state or federal regulations for transportation of excavator If unsure of regulations check with local authorities Check intended route for road width overhead clearances weight restrictions and traffic control regulations Special approval or permits may be required When doing this operation make sure that it is done on sol...

Page 284: ...bly and Loading on Carrier Counterweight Disassembly 25 min Crane Track Side Frame Disassembly 45 min Crane Front Disassembly 1 h 20 min Crane Sub Total 2 h 30 min Reassembly Front Assembly 2 h Crane Track Side Frame Assembly 1 h Crane Counterweight Assembly 1 h Crane Sub Total 4 h Total Sum 6 h 30 min ...

Page 285: ...ter frame support 5 Figure 157 CAUTION Be sure to clean all off all dirt and mud from tread surface of center frame and on side frames otherwise it may cause bolts to loosen Operate machine with side frames retracted only when loading and unloading machine or during driving for loading and unloading Do not retract side frames for excavating or during normal driving and operation If machine is oper...

Page 286: ...Tighten bolts to 288 kg m 2 083 ft lb NOTE Repeat procedure at other center frame support 4 After bolts for one side frame are fastened repeat Steps 1 thru 3 for other side frame 5 Store remaining bolts spacers and washers with machine Frame Extension 1 Remove five bolts harden washers and spacers 1 Figure 160 from side frame 2 to be extended NOTE Do not loosen two bolts 3 Figure 160 on guide 4 NO...

Page 287: ... 4 Raise side frame 3 Figure 161 slightly with jack and block 4 Extend arm 2 gradually to slide side frame out until it hits stop 5 After side frame 1 Figure 162 has slid into place lower superstructure to ground Remove cable 6 Install ten spacers harden washers and bolts 2 Figure 162 NOTE Tighten bolts to 288 kg m 2 083 ft lb NOTE Repeat procedure at other track frame support 7 After bolts for on...

Page 288: ...has been removed WARNING When transporting machine know width height length and weight Loading or unloading machine can be a dangerous operation Make sure to run engine at lowest speed setting and travel at slowest speed possible Make sure that ramp being used can handle weight of machine If required add blocking under ramp for additional support Make sure that ramp surface is free of grease or mu...

Page 289: ... shoe 2 6 m 8 6 arm 4 870 mm 15 12 3 650 mm 11 12 12 335 mm 40 6 72 0 metric tons 77 14 US tons 6 65 m 21 10 boom 650 mm shoe Model Arm Total Height Total Width Total Length Weight Boom and Shoes DX700LC 3 55 m 11 8 arm 4 220 mm 13 10 3 650 mm 11 12 13 250 mm 43 6 71 9 metric tons 79 23 US tons 7 7 m 25 3 boom 900 mm shoe 2 9 m 9 6 arm 4 520 mm 14 10 3 650 mm 11 12 13 400 mm 43 12 72 2 metric tons...

Page 290: ...ceeding a 15 angle Ramps steeper than this may cause a problem when loading or unloading 4 Set travel speed selector switch to O OFF position See Figure 165 5 Turn OFF auto idle selector button 1 Figure 166 The indicator symbol will be disappeared 6 Set engine speed to LOW IDLE 7 If machine is equipped with work equipment set work equipment at front and travel forward to load it Figure 164 FG01582...

Page 291: ...ck excavator onto trailer so counterweight end of excavator is positioned on ramp first See Figure 168 9 Extend bucket and arm cylinders to maximum length and then lower boom slowly 10 Set safety lever on LOCK position 11 Shut down engine by turning key to O OFF position Figure 171 12 Remove key from starter switch FG016155 15 Figure 168 Figure 169 FG015822 FG001091 Unlock Lock Figure 170 FG000175...

Page 292: ...s position height measurements may be different LIFTING WITH SLING 1 Refer to Specification on page 7 1 of this manual for information on weight and dimensions 2 Use properly rated cables and slings for lifting 3 Position machine for a level lift 4 Lifting cables should have a long enough length to prevent contact with machine Spreader bars may be required NOTE If spreader bars are used be sure th...

Page 293: ...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 294: ...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 295: ...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 296: ...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 297: ...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 298: ...OP000030 Troubleshooting 6 6 ...

Page 299: ...xial piston Discharging pressure 350 kg cm2 5 000 psi Maximum discharge quantity 2 x 436 liters min 2 x 115 2 U S gpm Hydraulic oil capacity Tank Level 350 liters 92 5 U S gal System 790 liters 208 7 U S gal Performance Digging 1 capability Bucket 35 7 34 8 metric tons 39 3 38 3 tons Arm 29 3 33 5 metric tons 32 3 36 9 tons Swing speed 7 1 rpm Travel speed High speed 4 6 km h 2 86 MPH Low speed 2 ...

Page 300: ...mm 13 5 Tumbler Distance C 4 730 mm 15 6 Track Length D 5 975 mm 19 7 C Weight Clearance E 1 525 mm 5 0 Shipping Height Boom F 4 063 mm 13 4 4 418 mm 14 6 5 015 mm 16 5 4 920 mm 16 2 4 750 mm 15 7 Shipping Height Hose G 4 220 mm 13 10 4 520 mm 14 10 5 130 mm 16 10 5 000 mm 16 5 4 870 mm 15 12 Shipping Width Std H 3 410 mm 11 2 House Width I 3 410 mm 11 2 Cab Width J 1 010 mm 3 4 Shoe Width K 650 m...

Page 301: ...OP001125 7 3 Specification ...

Page 302: ...rging pressure 350 kg cm2 5 000 psi Maximum discharge quantity 2 x 436 liters min 2 x 115 2 U S gpm Hydraulic oil capacity Tank Level 350 liters 92 5 U S gal System 790 liters 208 7 U S gal Performance Digging 1 capability Bucket 35 7 metric tons 39 3 tons Arm 29 3 metric tons 32 3 tons Swing speed 7 1 rpm Travel speed High speed 4 6 km h 2 86 MPH Low speed 2 8 km h 1 74 MPH Traction force High sp...

Page 303: ...m 13 5 Tumbler Distance C 4 730 mm 15 6 Track Length D 5 975 mm 19 7 C Weight Clearance E 1 525 mm 5 0 Shipping Height Boom F 4 063 mm 13 4 4 418 mm 14 6 5 015 mm 16 5 4 920 mm 16 2 4 750 mm 15 7 Shipping Height Hose G 4 220 mm 13 10 4 520 mm 14 10 5 130 mm 16 10 5 000 mm 16 5 4 870 mm 15 12 Shipping Width Std H 3 410 mm 11 2 House Width I 3 410 mm 11 2 Cab Width J 1 010 mm 3 4 Shoe Width K 900 mm...

Page 304: ...OP001125 Specification 7 6 Working Range FG015858 D C F E 8 A B J L I H d G M K Ground Figure 3 ...

Page 305: ...5 mm 6 0 2 050 mm 6 9 Min Swing Radius F 5 780 mm 18 12 5 790 mm 18 12 5 810 mm 19 1 5 230 mm 17 2 5 195 mm 17 1 Min Loading Height G 3 248 mm 10 8 3 950 mm 12 12 2 630 mm 8 8 3 080 mm 10 1 3 380 mm 11 1 Max Vertical Wall Depth H 5 730 mm 18 10 4 060 mm 13 4 6 515 mm 21 4 3 450 mm 11 4 3 305 mm 10 10 Max Loading Height I 8 320 mm 27 4 8 220 mm 26 12 8 660 mm 28 5 7 020 mm 23 0 6 940 mm 22 9 Max De...

Page 306: ...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 307: ...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 308: ...OP001125 Specification 7 10 ...

Page 309: ...7 Bucket 4 71 Installation 4 73 O ring 4 72 Shimming Procedures 4 73 Shimming Procedures for Installed Bucket 4 73 Teeth and Side Cutters 4 22 Tooth 4 71 C Cabin Light 2 56 Cabin Storage Compartments 2 66 Cabin Work Light Switch 2 12 Ceiling Cover 2 62 Charge Warning Light 2 24 Check and Confirmation After Stopping Engine 3 13 Cigarette Lighter 2 14 Circuit Breaker 2 56 Clock 2 23 2 38 Cold Weathe...

Page 310: ...77 G Gauges Engine Coolant Temperature Gauge 2 22 Fuel Gauge 2 22 Hour Meter 2 24 Hydraulic Oil Temperature 2 23 Multifunction Gauge 2 23 2 27 General Venting 4 89 H Handling a New Excavator 3 1 Handling of Accumulator 4 85 Hanger 2 67 2 68 Head Bolt Torques 4 54 Headlight Switch 2 11 Heater and Air Conditioner 2 49 Additional Operating Instruction 2 54 Control Panel 2 13 2 50 Filter 4 36 4 47 Loc...

Page 311: ...Operation 3 1 Operation In Extreme Cold 3 42 Extreme Heat 3 43 High Altitudes 3 45 Rainy or Humid Conditions 3 44 Salt Water Areas 3 44 Operation of All Switches 4 23 Operation Selection Display 2 46 Operation Under Unusual Conditions 3 42 Operational Checks Before Starting Engine 3 3 Operational Controls and Panels 2 6 Operator s Area 2 4 Operator s Compartment Light 2 56 Outer Air Cleaner Elemen...

Page 312: ...m up 3 9 Inspection Before Starting Engine 3 2 Operational Checks Before Starting Engine 3 3 Starting Engine Using a Booster Battery 3 7 Stereo 2 55 Audio Control Panel 2 10 Structural Damage 4 54 Suction Strainer 4 52 Sun Visor 2 67 Swing Bearing 4 26 Gear and Pinion 4 34 Motor 4 89 Reduction Device 4 19 4 33 4 43 4 49 System 6 4 Switches Auto Idle Selector Button 2 34 Automatic Travel Speed Cont...

Page 313: ...tch Optional 2 15 Trenching Mode Selector Button 2 33 Troubleshooting 6 1 U Unloading and Loading 5 6 Up Arrow Button 2 35 V Venting and Priming Hydraulic System 4 88 General Venting 4 89 Hydraulic Cylinders 4 88 Main System Pump 4 88 Swing Motor 4 89 W Warning Light Switch 2 12 Washer Button 2 14 Water Separator 4 18 Weight of Workload Materials 7 6 Window Washer Liquid 4 21 Windows Door Window H...

Page 314: ...950106 00012E Index 8 6 ...

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