Doosan DX27Z Operation And Maintenance Manual
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Doosan DX27Z Operation And Maintenance Manual

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DOOSAN reserves the right to improve its products continuously, delivering the best possible product to
the marketplace. These improvements can be implemented at any time with no obligation to change
materials previously sold. It is recommended that consumers periodically contact their distributors for most
recent documentation on purchased equipment.
This documentation may include attachments and optional equipment not available in your machine's
package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
K1028289E Operation and Maintenance Manual
DX27Z
Operation and Maintenance Manual
K1028289E
Serial Number 5001 and Up
December 2006
Copyright Doosan 2006

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Summary of Contents for Doosan DX27Z

  • Page 1 Serial Number 5001 and Up December 2006 DOOSAN reserves the right to improve its products continuously, delivering the best possible product to the marketplace. These improvements can be implemented at any time with no obligation to change materials previously sold. It is recommended that consumers periodically contact their distributors for most recent documentation on purchased equipment.

  • Page 3: Table Of Contents

    Table of Contents Safety ..................1-1 To the Operator of a Excavator............1-1 Location of Safety Labels ..............1-5 Summary of Safety Precautions for Lifting in Digging Mode ..1-12 Unauthorized Modifications............. 1-13 General Hazard Information ............1-13 Before Starting Engine ..............1-23 Machine Operation................
  • Page 4 Hanger ..................... 2-28 Cup Holder ..................2-28 Emergency Glass Breaking Tool ........... 2-28 Operation..................3-1 To Handle a New Excavator ............3-1 Starting and Stopping the Engine ........... 3-2 Safety Lever ..................3-13 Travel ....................3-14 Operating Instructions ..............3-19 Operating Precautions ..............3-23 Parking Excavator ................
  • Page 5 Bucket ....................4-40 Electrical System................4-46 Engine Cooling System ..............4-49 Handling of Accumulator ..............4-53 Long Term Storage ................ 4-54 Maintenance in Special Conditions ..........4-55 Track Tension ................. 4-56 Venting and Priming Hydraulic System ........4-58 Transportation ................5-1 Loading and Unloading ..............
  • Page 6 Table of Contents K1028289E...

  • Page 7: Safety

    OP000522 Safety TO THE OPERATOR OF A EXCAVATOR DANGER! Unsafe use of the excavator could lead to serious injury death. Operating procedures, maintenance equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
  • Page 8 If there is any question about whether your product complies with the applicable standards and regulations of your country, consult DOOSAN or your DOOSAN distributor before operating the machine. Safety...
  • Page 9 SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents.
  • Page 10 If you are unsure about the safety of any procedures, contact a DOOSAN distributor. Safety OP000522...

  • Page 11: Location Of Safety Labels

    LOCATION OF SAFETY LABELS CANOPY TYPE FG007474 Figure 1 There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs. Make sure that all the warning signs are legible.
  • Page 12 1. Warnings for Operation, Inspection and Maintenance (190-00688, 190-00092) AVOID DEATH OR SERIOUS INJURY. - READ AND UNDERSTAND OPERATION MANUAL AND SAFETY LABELS prior to operating this machine. Never get in under the machine while it is being jacked up with boom and ar m.
  • Page 13 3. Warnings When Opening a Front Window (2190-3388, 190-00093) 2190-3388 190-00093 FG000665 4. Warnings for a High-pressure Cylinder (190-00122) 190-00122 ARO1110L Safety OP000522...
  • Page 14 5. Warnings When Adjusting Track Tension (2190-3386A, 190-00521) 2190-3386A 190-00521 ARO1120L 6. Warnings for Leaving Operator's Seat (190-00693, 190-00094) 190-00693 190-00094 ARO1140L Safety OP000522...
  • Page 15 7. Warnings for Batteries Maintenance (2190-2533A, 190-00100) 2190-2533A 190-00100 ARO1150L 8. Warnings for High Temperature Hydraulic Oil (190-00691, 190-00097) 190-00097 190-00691 ARO1160L Safety OP000522...
  • Page 16 9. Warnings for Hot Coolant (190-00692, 190-00097) 190-00097 ARO1170L 10. Warnings for Rotating Parts (190-00694, 190-00095, 190-00557) 190-00095 190-00557 ARO1190L Safety OP000522 1-10...
  • Page 17 11. Warning Tag - Used When Inspection and Maintenance (190-00695, 190-00098) WARNING DO NOT OPERATE when performing inspection or maintenance 190-00695 190-00098 ARO1200L 12. Keep Out of the Swing Area (2190-3380A, 190-00163) 2190-3380A 190-00163 FG008064 Safety OP000522 1-11...

  • Page 18: Summary Of Safety Precautions For Lifting In Digging Mode

    WARNING! If you need more information or have any questions or concerns about safe operating procedures or working the excavator correctly in a particular application or in the specific conditions of your individual operating DOOSAN environment, please consult your local representative.

  • Page 19: Unauthorized Modifications

    Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner will be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not...
  • Page 20 Inside Operator's Cabin When entering the operator's cabin, always remove all mud and oil from the soles of your shoes. If you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident. After using the ashtray, make sure that any matches or cigarettes are properly extinguished, and be sure to close the ashtray.
  • Page 21 Breathing Masks, Ear Protection May Be Required Do not forget that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause disabling or permanent injuries. equivalent continuous A-weighted sound...
  • Page 22 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a DOOSAN genuine part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.
  • Page 23 Mounting and Dismounting Before getting on or off the machine, if there is any oil, grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts. Never jump on or off the machine.
  • Page 24 Precautions When Handling Fluids at High Temperature Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at highest temperatures and the radiator and hydraulic tank are still under pressure. Attempting to remove the cap, drain the oil or coolant, or replace the filters may lead to serious burns.
  • Page 25 Injury from Work Equipment Do not enter or put your hand, arm or any other part of your body between movable parts, such as between the work equipment and cylinders, or between the machine and work equipment. If the control levers are operated, the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury.
  • Page 26 Reinstallation, recertification and/or replacement of the system may be necessary. Contact your DOOSAN distributor for available safety guards and/or recommendations to prevent danger of getting hit by objects that could strike the operator's cabin. Make sure that all other work site crew members are kept well away from the excavator and safe from possible hazards.
  • Page 27 • When carrying out disassembly or maintenance of accumulator, when disposing accumulator, the charged gas must be properly released. Contact your DOOSAN distributor. • Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under pressure penetrate...
  • Page 28 Emergency Exit This machine is equipped with a glass breaking tool. It is behind the operator seat in the upper left corner of the cabin. This tool can be used in case of an emergency situation that requires the breaking of glass to exit from the operator's cabin.

  • Page 29: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make sure the ground surface is as hard and horizontal as possible before carrying out operations.
  • Page 30 Minimum levels of insurance coverage, work permits or certification, physical barriers around the work site or restricted hours of operation may be mandated by governing authorities. There may also be regulations, guidelines, standards or restrictions on equipment that may have to be followed local requirements.
  • Page 31 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 safety guards must be in place, to protect against injury while the machine is being operated.
  • Page 32 Before Operating Machine If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions.

  • Page 33: Machine Operation

    MACHINE OPERATION When Swinging or Changing Direction of Travel Before operating the machine or the work equipment, always observe the following precautions to prevent serious injury or death. • Start and operate the machine only while seated. • When changing direction travel from...
  • Page 34 Travel Precautions T R A V E L P O S T U R E Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops while the machine is traveling. It will be impossible to operate the steering. Attachment control levers should not be operated while traveling.
  • Page 35 Traveling on Slopes Never jump onto a machine that is running away to stop it. There is danger of serious injury. Traveling on slopes could result in the machine tipping over or slipping. On hills, banks or slopes, carry the bucket approximately 20 - 30 cm (8 - 12 in) above the ground.
  • Page 36 Do not carry out deep digging under the front of the machine. The ground under the machine may collapse and cause the machine to fall. Working heavy loads over loose, soft ground or uneven, broken terrain can cause dangerous side load conditions and possible tipover and injury.
  • Page 37 To avoid hitting the work equipment, always do the following: • When working in tunnels, on bridges, under electrical wires, or when parking the machine or carrying out other operations in places with limited height, be extremely careful not to hit the bucket or other parts.
  • Page 38 Operate Carefully 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.
  • Page 39 Parking Machine Avoid making sudden stops, parking machine wherever it happens to be at the end of the workday. Plan so the excavator will be on firm, level ground away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff.
  • Page 40 Never Let Anyone Ride on Attachment Never let anyone ride on any work attachment, such as the bucket, crusher, grapple, or clamshell (grab bucket). There is a danger of the person falling and suffering serious injury. ARO1310L Figure 28 Safety OP000522 1-34...

  • Page 41: Maintenance

    DO NOT OPERATE device and a length of chain or cable to keep the safety lever in the fully lowered, nonactive position. when performing inspection or maintenance Warning tags, for controls are available from DOOSAN distributors. 190-00695 ARO1320L Figure 29...
  • Page 42 Proper Tools Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. There is danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness. HDO1037L Figure 31 Use of Lighting...
  • Page 43 Fire Prevention and Explosion Prevention All fuels, most lubricants and some coolant mixtures are flammable. Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire. Store all fuels and all lubricants properly marked containers and away from all unauthorized persons.
  • Page 44 Burn Prevention When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator.
  • Page 45 Precautions When Working on Machine When carrying out maintenance operations on the machine, keep area around your feet clean and tidy to prevent falls. Always do the following: • Do not spill oil or grease. • Do not leave tools laying about. •...
  • Page 46 If necessary depending on the type of failure, please contact your DOOSAN distributor for repairs. Precautions with High-pressure Lines, Tubes and Hoses When inspecting or replacing high-pressure piping or hoses, check to verify that the pressure has been released from the circuit.
  • Page 47 Waste Materials Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. To prevent pollution of the environment, always do the following: •...

  • Page 48: Battery

    BATTERY Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following: • Do not smoke or bring any flame near the battery. •...
  • Page 49 Boost Starting or Charging Engine Batteries If any mistake is made in the method of connecting the booster cables, it may cause an explosion or fire. Always do the following: • Turn off all electrical equipment before connecting leads to the battery. This includes electrical switches on the battery charger or boost starting equipment.

  • Page 50: Towing

    Shackle • If the engine on the problem machine will not start or there is a failure in the brake system. always contact your DOOSAN distributor. Towing Wire FG000669 • Never go between the towing machine and the Figure 43 towed machine during the towing operation.

  • Page 51: Shipping And Transportation

    SHIPPING AND TRANSPORTATION Obey State and Local Over-the-Road Regulations Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.

  • Page 52: Excavator Rated Lift Capacity Tables

    EXCAVATOR RATED LIFT CAPACITY TABLES WARNING! Let everybody be away from the boom cylinder. While lifting operation, boom, arm, bucket hoses might burst and then high-pressure oil will be ejected at high-speed. If that failure mode takes place, handling weight or front structure might fall by its gravity to the ground to cause fatal injury to the person.
  • Page 53 Avoid traveling with a suspended load. Before swinging (or if required, traveling), bring the load into an arm position (radius and height) that has a safer weight capacity rating and adequate movement clearance. The operator and all work site personnel should be thoroughly familiar with safety instructions procedures within...
  • Page 54 TRACK WIDTH 1.62 m (5' 4") TRACK BOOM 2.0 m (6' 6") 1.1 m (3' 7") BUCKET SAE 0.08 m (CECE 0.07 m SHOE 300 mm (11.8") RATING OVER FRONT RATING OVER SIDE OR 360 degree WITHOUT DOZER UNIT 1,000 kg (1,000 lb) METRIC MAX.
  • Page 55 TRACK WIDTH 1.62 m (5' 4") TRACK BOOM 2.0 m (6' 6") 1.1 m (3' 7") BUCKET SAE 0.08 m (CECE 0.07 m SHOE 300 mm (11.8") RATING OVER FRONT RATING OVER SIDE OR 360 degree WITH DOZER UNIT 1,000 kg (1,000 lb) METRIC MAX.
  • Page 56 TRACK WIDTH 1.62 m (5' 4") TRACK BOOM 2.0 m (6' 6") 1.3 m (4' 3") BUCKET SAE 0.08 m (CECE 0.07 m SHOE 300 mm (11.8") RATING OVER FRONT RATING OVER SIDE OR 360 degree WITHOUT DOZER UNIT 1,000 kg (1,000 lb) METRIC MAX.
  • Page 57 TRACK WIDTH 1.62 m (5' 4") TRACK BOOM 2.0 m (6' 6") 1.3 m (4' 3") BUCKET SAE 0.08 m (CECE 0.07 m SHOE 300 mm (11.8") RATING OVER FRONT RATING OVER SIDE OR 360 degree WITH DOZER UNIT 1,000 kg (1,000 lb) METRIC MAX.
  • Page 58 Safety OP000522 1-52...

  • Page 59: Operating Controls

    OP000523 Operating Controls The "Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-2 “Operator's Area” on page 2-4 “Operational Controls and Panels” on page 2-6 “instrument Panel” on page 2-13 “Stereo (Optional)” on page 2-18 “Fuse boxes”...

  • Page 60: Component Locations

    COMPONENT LOCATIONS FG008644 Figure 1 Operating Controls OP000523...
  • Page 61 Reference Reference Description Description Number Number Boom Counterweight Boom Cylinder Seat Arm Cylinder Rubber Crawler (Track) Blade Bucket Cylinder Blade Cylinder Bucket Linkage Travel Motor (Dump) Linkage Lower Roller Bucket Idler Swing frame Track Spring Cover Swing Bracket Fuel Tank Swing Cylinder Hydraulic Oil Tank Attachment Control Levers...

  • Page 62: Operator's Area

    OPERATOR'S AREA FG008654 Figure 2 Operating Controls OP000523...
  • Page 63 Reference Reference Description Description Number Number Instrument Panel Storage Compartment (See page 2-13) (See page 2-27) Cigar Lighter (Optional) Heater (Optional) (See page 2-10) Fuse Box Travel Levers (See page 2-19) (See page 3-15) Left-hand Work Lever (Joystick) Right-hand Work Lever (Joystick) (See page 3-22) (See page 3-20) Safety Lever...

  • Page 64: Operational Controls And Panels

    OPERATIONAL CONTROLS AND PANELS FG008655 Figure 3 Operating Controls OP000523...
  • Page 65 Reference Reference Description Description Number Number Starter Switch Cigar Lighter (Optional) Travel Speed Selector Switch Windshield Washer Switch (Optional) Work Light Switch Wiper Switch (Optional) Quick Clamp Switch (Optional) Heater Switch (Optional) Travel Alarm Switch (Optional) Horn Switch Warning Light Switch (Optional) OP000523 Operating Controls...
  • Page 66 1. Starter Switch A four-position starter switch is used to start or shut down engine for equipment operation. Turning the switch to this position turns the engine "OFF" along with its electrical system. In this position the engine is "OFF" but the interior cabin light is functional.
  • Page 67 3. Work Light Switch This switch is used to control the work lights and the cabin work lights, if unit is equipped with them. In this position, all lights are turned "OFF." In this position, the work lights and all instrument panel lights and control switch lights are turned "ON"...
  • Page 68 5. Travel Alarm Switch (Optional) If unit is equipped with a travel alarm buzzer, push this switch to active it, whenever traveling. In this position, the travel alarm system is turned "OFF." In this position, the travel alarm will sound while traveling.
  • Page 69 8. Windshield Washer Switch (Optional) While the windshield wiper is running, depress the washer switch to spray windshield washer fluid onto the windshield. Use only the proper windshield washer fluid in the system. In this position, the washer is "OFF." In this position, the windshield washer sprays fluid.
  • Page 70 11. Horn Switch Press button on top of left-hand work lever (joystick) to sound horn. FG007495 Figure 14 Operating Controls OP000523 2-12...

  • Page 71: Instrument Panel

    INSTRUMENT PANEL FG007496 Figure 15 Reference Reference Description Description Number Number Engine Coolant Temperature Engine Coolant Temperature Gauge Warning Light Fuel Gauge Air Cleaner Clogged Warning Light Hour Meter Fuel Level Warning Light Engine Oil Pressure Warning Light Preheat Indicator Light Charge Warning Light Quick Clamp Indicator Light Operating Controls...
  • Page 72 1. Engine Coolant Temperature Gauge WHITE The colored bands indicate the temperature of the engine coolant. BLUE BLUE ZONE ( ) - Indicates temperature is lower than the normal operating temperature. WHITE ZONE ( ) - Indicates temperature is within the normal operating range.
  • Page 73 3. Hour Meter The hour meter is used to indicate the total number of running hours on the engine. The meter will flash every four seconds when the engine is running to indicate that it is functioning properly. Figure 18 4.
  • Page 74 6. Engine Coolant Temperature Warning Light This indicator light will turn "ON" when coolant temperature rises excessively. CAUTION! When this light turns "ON," immediately stop work. HAOD350L Allow the engine to run at low idle speed until the Figure 21 temperature gauge registers in the "WHITE"...
  • Page 75 9. Preheat Indicator Light This indicator light will turn "ON" when preheating is completed. This light turns "ON" after fifteen seconds when the starter switch is turned to the preheating position. Figure 24 10. Quick Clamp Indicator Light This indicator light will turn "ON" when the quick clamp switch is in the "...

  • Page 76: Stereo (Optional)

    STEREO (OPTIONAL) Before operating the stereo, read operation manual enclosed with stereo. 5, 6 AM/FM SCAN TAPE SOUND TUNE FG007499 Figure 26 Reference Reference Description Description Number Number Power / Volume Control Preset Station Sound Mode Selection Tape Ejection Band Selection Tape Loading Slot Tuning Up / Down Scan Function / Auto Store...

  • Page 77: Fuse Boxes

    FUSE BOXES Fuses prevent electrical devices from overloading shorting. There is a fuse box in the electric box which is under the seat. A decal attached to the fuse box's cover indicates the function and amperage of each fuse. Spare fuses are mounted on the inside of fuse box's cover. (One each of a 10A, 15A, 20A and 30A.) Change a fuse if the element separates.

  • Page 78: Miscellaneous Electrical Devices

    WARNING! HAAE2120 Figure 31 When changing the fusible link, replace the fusible link with the same capacity part. Otherwise, a fire could break wiring harness and/or other components of the circuit. Always use original DOOSAN parts. Operating Controls OP000523 2-20...

  • Page 79: Heating System (Optional)

    HEATING SYSTEM (OPTIONAL) Location of Vents Heater FG008656 Figure 32 The heater is installed on the right side of the operator's cabin. If necessary, the operator can control inner temperature using the temperature control switches installed on the right side of the operator's cabin. Operating Controls OP000523 2-21...
  • Page 80 Control Switches Heater Switch This switch is used to control the speed of the blower fan used for heater. In this position, fan is "OFF." In this position, fan runs at "LOW" speed. In this position, fan runs at "HIGH" speed. BPO0310L Figure 33 Additional Operating Instructions...

  • Page 81: Seat Adjustment

    SEAT ADJUSTMENT 1. Front/Rear Adjustment Pulling up the adjustment lever (1, Figure 34) allows the seat to be moved forward and backward over a range of 210 mm (8.27 in). 2. Backrest Adjustment Lifting up the adjustment lever (2, Figure 34) under the front of the seat adjusts the seat back to obtain the desired backrest angle.
  • Page 82 Seat Belt Locking and Unlocking Insert belt end (1, Figure 35) into the buckle (2). Pull the belt to check that belt end is locked into buckle. Adjust belt length so it is comfortably tight against the operator's pelvic region (hipbone). HAOB140L Figure 35 Press the button (3, Figure 36) in the center of buckle...

  • Page 83: Front Windows

    FRONT WINDOWS WARNING! When leaving operator's seat, set the safety lever to "LOCK" position (Figure 37), if not a serious accident could occur by accidentally moving the work levers. Front Upper Window FG007539 The front upper window can be housed in the cabin's Figure 37 ceiling.
  • Page 84 Closing the Window WARNING! Be careful that your hands are not caught in window frame. Lower bucket to ground. Set safety lever (Figure 37) on "LOCK," and shut down FG008066 engine. Figure 39 Holding lock levers (1, Figure 39) of front window with left and right-hand, turn the lock levers towards outside edge of window to release the lock.

  • Page 85: Door Side Latch

    DOOR SIDE LATCH The door side latch (1, Figure 42) is used to secure the door to the side of the cabin when it is opened. Keep the door closed and locked when machine NOTE: is not in use. FG007543 Figure 42 To release door from side of cabin, push the latch lever (2, Figure 43) down.

  • Page 86: Hanger

    HANGER A hanger (1, Figure 46) is located on the upper left side of the operator's cabin. WARNING! Do not hang anything that will easily fall down, or will impair your view out of the cabin. FG007547 Figure 46 CUP HOLDER There is a cup holder on the right side of the operator's seat (Figure 47).

  • Page 87: Operation

    OP000470 Operation TO HANDLE A NEW EXCAVATOR All excavators are inspected and adjusted before leaving the factory. However, it is required that the operator follow these steps during the initial break-in period. Failure to follow these steps may result in damage to the equipment or reduced performance.

  • Page 88: Starting And Stopping The Engine

    Lubrication and Filters Change engine oil and replace oil filter after first 50 hours of operation. Change swing reduction device oil after first 250 hours of operation. Change hydraulic oil return filter after first 250 hours of operation. Replace travel and reduction gear oil after first 250 hours of operation.
  • Page 89 condition, and are functioning correctly. Stop operation and correct any malfunction before continuing work. Operational Checks Before Starting Lock Engine Unlock WARNING! When leaving operator's seat, set the safety lever to "LOCK" (Figure 1) position, if not a serious accident could occur by accidentally moving the travel or work levers.
  • Page 90 Engine Start WARNING! Start the engine after sounding horn and making sure that there are no people or obstacles in the area. Perform steps “Operational Checks Before Starting Engine” on page 3-3. Set engine speed control lever slightly above "LOW IDLE"...
  • Page 91 INDICATOR INSTRUMENT PANEL LIGHT OR GAUGE READING Engine Coolant Temperature Gauge White Fuel Gauge White Charging Warning Light Engine Oil Pressure Warning Light Engine Coolant Temperature Warning Light Check color of exhaust smoke. • No color or light blue - Engine is running in good condition.
  • Page 92 Cold Weather Starting WARNING! DO NOT USE STARTING FLUIDS. The preheat system could cause the starting fluid to explode. Starting fluids should never be used. Perform steps "Operational Checks Before Starting Engine." Set engine speed control lever slightly above "LOW IDLE"...
  • Page 93 After the preheat completion, immediately turn starter " " switch to (START) position (Figure 9). Engine should start in approximately five seconds. WARNING! If the engine does not start after approximately fifteen seconds of cranking, release the starter FG001372-1 switch. Wait about five minutes and repeat above Figure 9 step.
  • Page 94 IMPORTANT The machine has a 12V (-) negative ground electrical system. Use the same capacity 12V booster batteries when jump starting engine. If the batteries are drained during starting procedures, jump start engine using auxiliary or booster batteries according to the following procedure: Connecting the Booster Battery Shut down engine of the machine on which booster...
  • Page 95 Hydraulic System Warm-up WARNING! If a problem or abnormal operation occurs, immediately shut down engine. Allow excavator to reach normal operating temperature before starting work, especially in cold weather. The correct operating temperature of the hydraulic oil is 50° - 80°C (120° - 175°F). Make sure to follow the procedures listed here for hydraulic fluid warm-up.
  • Page 96 Hydraulic System Warm-up – Cold Weather Run engine at "LOW IDLE" (no load) for five minutes (Figure 15). FG007557 Figure 15 Run engine for approximately five minutes set at the middle of the speed range, without a load (Figure 16). FG007561 Figure 16 Set safety lever (1, Figure 17) on "UNLOCK"...
  • Page 97 Set engine speed control dial to "HIGH IDLE" (Figure 19). Repeat Step 4 for five minutes. If working speeds continue to be slow, continue to operate, but use extreme caution because the machine function may be erratic. Check clearance fully raise front attachment.
  • Page 98 Shut down engine by turning key to "O" (OFF) position (Figure 23). Remove key from starter switch. FG008382 Figure 23 Check and Confirmation After Stopping Engine Repair excavator, if there are any coolant or oil leaks. Inspect front attachment under carriage abnormal appearances.

  • Page 99: Safety Lever

    "RELEASE/UNLOCK" position and all levers and pedals are in "NEUTRAL," return the safety lever to "LOCK" position, shut down engine and contact your nearest DOOSAN dealer. There malfunction with the system. If the pilot cutoff switch mounted on switch NOTE: panel is not pressed to "I"...

  • Page 100: Travel

    TRAVEL WARNING! Before operating the travel levers, make sure that know which direction machine 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).
  • Page 101 Travel Control Lever Operation To travel straight (Figure 27), push both travel control levers/pedals fully forward or backwards. The farther the levers/pedals are pressed, the faster the travel speed. "X" is the sprocket end of the track. NOTE: "X" FG007567 Figure 27 Pivot turns (Figure 28) are made by rotating only one track forward or backward.
  • Page 102 General Travel Instructions Set engine speed control lever (Figure 31) on desired speed. FG007564 Figure 31 Set safety lever on "UNLOCK" position, and folding the front, raise it 40 - 50 cm (16 - 20 in) above ground. Lock See Figure 32. Unlock 40 ~ 50 cm FG007571...
  • Page 103 On rough, frozen or uneven terrain, travel slowly. 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.
  • Page 104 If dirt or mud builds up in the track frame, raise each track and rotate and clean that track. CAUTION! When using the boom and arm to lift any portion of the machine, roll the bucket until the round base is against the ground.

  • Page 105: Operating Instructions

    OPERATING INSTRUCTIONS Engine Speed Control Engine speed can be manually adjusted using the engine speed control lever. Increase engine speed by pulling the lever back. Decrease engine speed by pushing the lever forward. IMPORTANT The engine speed control system has been set at the FG007576 factory and should not require adjustment as part of Figure 40...
  • Page 106 The following is not a mechanical malfunction but a NOTE: proper phenomenon 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.
  • Page 107 Change Machine Control Pattern by Select Valve (If Equipped) WARNING! Check surrounding area before swinging. When operating a lever while in auto idle, do it carefully, because the engine speed will increase rapidly. FG007624 Figure 46 When starting work, move work levers (joysticks) NOTE: slowly and check movement of swing and front <ISO PATTERN>...
  • Page 108 Work Levers (Joysticks) (BHL Style) Left-hand Work Lever (Joystick) (Figure 46 and Figure Boom down Boom up Left swing Right swing The swing brake is spring applied and hydraulically NOTE: released. It is always engaged when the work lever (joystick) is in "NEUTRAL" or the engine is shut FG007583 down.

  • Page 109: Operating Precautions

    OPERATING PRECAUTIONS WARNING! Do not rest your feet on the travel pedals during normal machine operation. Unexpected machine travel may occur in this situation. Before starting work, investigate terrain soil condition. Level ground and drain area if necessary. Install window guards when working where there is a possibility of falling rocks or other objects.
  • Page 110 Do not use machine travel or swing when the bucket is in the ground to provide additional breakout force. See Figure 54. FG007590 Figure 54 Do not use machine weight to provide additional breakout force. See Figure 55. When working on soft or muddy ground, make sure that the machine is not sinking.
  • Page 111 11. Make sure that there is adequate clearance from overhead electrical supply lines. See Figure 58. FG007594 Figure 58 12. If the excavation is in an underground location or in a building, make sure that there is adequate overhead clearance and that there is adequate ventilation. See Figure 59.
  • Page 112 15. Do not operate travel lever quickly when traveling in high range. • Avoid sudden starts. • When traveling in direction come to a complete stop before reversing directions. Do not rock excavator back and forth with levers. • Avoid sudden stops. Return levers to neutral by hand.
  • Page 113 IMPORTANT If the center joint, Swivel bearing or pinion gear are submerged in water, mud or sand, they need to be serviced, either lubricated or in some cases rebuilt. addition, other component that submerged, such as a bucket pin, should be lubricated.

  • Page 114: Parking Excavator

    PARKING EXCAVATOR WARNING! Park machine on firm, level ground. Avoid parking on slopes. If excavator must be parked on a slope, block tracks and place bucket teeth in ground. See Figure 64. FG007608 Figure 64 Park machine on firm, level ground. Lower bucket to ground as shown in Figure 65.

  • Page 115: Towing Procedure

    TOWING PROCEDURE Cloth WARNING! Never use a damaged wire rope or chain. They could brake and cause a serious accident. Towing Wire Always wear gloves when handling a chain or wire rope. When towing excavator use a wire rope or chain capable of handling the load.

  • Page 116: Hydraulic Breaker

    If a hydraulic breaker is installed, consider equipment's stability and suitability for such modification. Also, consider hydraulic oil pressure and quantity. When selecting a hydraulic breaker consult with a DOOSAN distributor or sales agency. Hydraulic Hoses and Tubing for Breaker When installing hydraulic breaker, assemble according to drawings provided with kit.
  • Page 117 Hydraulic Breaker Operation Hydraulic pressure and flow settings may need to be NOTE: changed. Refer to the Maintenance Section of this manual for further information. Make sure to read and understand the breaker user's manual. Inspect all mechanical and hydraulic connections. Do not use the breaker as a hammer.
  • Page 118 Do not allow the breaker body to go into water if not equipped for underwater operation. The breaker seal can be damaged and allow rust, foreign material or water to enter the hydraulic system and cause damage. Only insert the breaker tool into water. See Figure 72. FG007613 Figure 72 Do not any lifting or towing with a breaker.
  • Page 119 100% 500 Hours 100 Hours Work These service intervals only apply, when a genuine DOOSAN oil and filter are used. If any other brands are used, the guaranteed changed interval should be reduced in half. FILTER (First Replacement) HYDRAULIC OIL...
  • Page 120 PTO Pedal Valve (Optional) Breaker Operation Using the Pedal Valve Pushing down on the top end of the PTO pedal, operates the breaker. Releasing the pedal stops the breaker. FG007599 Figure 77 Locking the Pedal When rotating is not needed, the pedal can be locked by using the prop rod (1) locking device.
  • Page 121 Boom Swing Pedal This pedal, located near the operator's right foot swings the boom. The pedal is used to dig along a gully wall or a retaining wall. How to operate boom Pressing the left of the pedal (1, Figure 80) swings the boom to the left, while pressing the right of the pedal (2, Figure 80) swings the boom to the right.
  • Page 122 Figure 83 Precautions for Blade Use The blade control lever, located on the right-hand side of the driver's seat, controls the operation of the blade. When the lever is released, it goes to the NEUTRAL position and the blade stops immediately. Use the blade only for earth moving.

  • Page 123: Operating Techniques

    OPERATING TECHNIQUES Lifting IMPORTANT There may be local or government regulations, about the use of excavators for the lifting of heavy loads. Always contact your local and government agencies in regards to these regulations. Lifting Unknown Weight When loads are not accurately known are to be lifted, the FRONT LIFT person responsible for the job shall ascertain that the weight ZONE...
  • Page 124 Align the boom with the forward direction of machine travel. Maintain this boom position when turning the machine. Turn only when necessary, at the slowest speed, and at a wide turning radius. Use the shortest lifting radius distance possible. Keep the load as close to the ground as conditions will permit.

  • Page 125: Operation Under Unusual Conditions

    OPERATION UNDER UNUSUAL CONDITIONS See “Long Term Storage” on page 4-54 for other NOTE: recommendations. Operation In Extreme Cold If machine is to be operated in extreme cold weather temperatures, certain precautions must be taken to assure continued normal operation. The following paragraphs detail checks to be made to be certain the machine is capable of operating at these temperatures.
  • Page 126 If cold weather starting aid must be used, see "Engine Starting" COLD WEATHER START portion of this manual. 10. Clean off all mud, snow and ice to prevent freezing. Cover machine with tarpaulin if possible, keep ends of tarpaulin from freezing to ground. Operation in Extreme Heat Continuous operation of the machine in high temperatures may cause the machine to overheat.
  • Page 127 Do not park machine in sun for long periods of time. When practical park machine under cover to protect it from sun, dirt and dust. Cover inactive machine with tarpaulin suitable shelter available. Protect engine compartment, transmission and hydraulics from entrance of dust.
  • Page 128 Operation in Rainy or Humid Conditions Operation under rainy conditions is similar to that as in extreme heat procedures listed previously. Keep all exposed surfaces coated with preservative lubricating oil. Pay particular attention to damaged or unpainted surfaces. Cover all paint cracks and chip marks as soon as possible to prevent corrosive effects.

  • Page 129: Inspection, Maintenance And Adjustment

    OP000524 Inspection, Maintenance and Adjustment PREVENTIVE MAINTENANCE Routine maintenance and inspections are required to keep your machine in the correct operating condition. The following pages list the inspection intervals, the system or component checks, and location references. The following pages list the service checks and their NOTE: required intervals.
  • Page 130 7-11, Hwasu-dong, Dong-gu, Incheon, Korea K1011647B K1011647B FG009008 Figure 3 Component Serial Numbers There many serial numbers each traceable component of the machine. For example, the engine serial number is stamped on the rear left side of the engine block, above the starter.

  • Page 131: Preliminary Work Machine Setup For Maintenance

    PRELIMINARY WORK MACHINE SETUP FOR MAINTENANCE When performing maintenance specified in this manual, always park the excavator as follows. Certain types of maintenance may require the NOTE: machine to be positioned differently. Always return machine to this position. Park on firm, level ground. Lower bucket to ground.
  • Page 132 Shut down engine by turning key to "O" (OFF) position. Remove key from starter switch. WARNING! engine must while performing maintenance, use extreme care. Always have one person in the cabin at all times. Never leave the cabin with the engine running. FG001364 Figure 8 Before starting maintenance work, hang up a tag, "Do...

  • Page 133: Table Of Recommended Lubricants

    TABLE OF RECOMMENDED LUBRICANTS Refer to the Maintenance Intervals Table for NOTE: application points. Ambient Temperature Kind of Reservoir Fluid °F 50 °C SAE 10W-30 Engine Oil * SAE 10W-40 Engine Oil SAE 15W-40 SAE 90 and API GL5 Swing Drive Case Gear Oil * SAE 80W-90 and API GL5...
  • Page 134 Hydraulic oil change interval is 2,000 hours, only when DOOSAN Genuine Oil is used. If other brands of oil is used, guaranteed change interval is 1,000 hours. API: American Petroleum Institute. ACEA: Association des Constructeurs Europens d'Automobiles. ASTM: American Society of Testing and Material.

  • Page 135: Fluid Capacities

    FLUID CAPACITIES Component Capacity Engine Oil Pan with Filter 5.5 liters (1.45 U.S. gal.) Cooling System 3.5 liters (0.92 U.S. gal.) Fuel Tank 30 liters (7.9 U.S. gal.) Hydraulic Oil Tank Level 30 liters (7.9 U.S. gal.) System 45 liters (11.8 U.S.
  • Page 136 Description of Lubrication and Service Chart 12,14 250h 500h 1000h 2000h FG007707 Figure 10 Inspection, Maintenance and Adjustment OP000524...
  • Page 137 SERVICE DATA Service Interval Items to Check Service Qty. 1000 2000 Coolant Radiator 3.5 L (Antifreeze) Front & Blade Grease F100 Boom Swing Grease F100 Cylinder Swing Gear Grease Swing Bearing Grease Travel Reduction Gear Oil 0.5 L V, F Device (80W90) Engine Oil...

  • Page 138: Maintenance Intervals

    MAINTENANCE INTERVALS SERVICE ITEM PAGE 10 Hour / Daily Service Grease Dozer, Boom Swing and Front Attachment Pins (For First 100 Hours) 4-12 Check Engine Oil Level 4-12 Check Level of Hydraulic Oil Tank 4-13 Check for Leaks in Hydraulic System 4-14 Check Fuel Level 4-15...

  • Page 139: Service Item

    Major Parts - Periodic Replacement 4-37 12,000 Hour / Six Year Service Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) 4-38 ** These checks need to be completed by an authorized DOOSAN dealer. Inspection, Maintenance and Adjustment OP000524 4-11...

  • Page 140: 10 Hour / Daily Service

    10 HOUR / DAILY SERVICE Grease Dozer, Boom Swing and Front Attachment Pins (For First 100 Hours) WARNING! Do not remove the grease fitting until the pressure is entirely bleed off by loosening grease fitting slowly to avoid fatal wound. FG000500 Let anybody never be in the blowing direction.

  • Page 141: Check Level Of Hydraulic Oil Tank

    Engine oil level must be between "HIGH" and "LOW" marks on dipstick. If oil is above "HIGH" mark on dipstick, some NOTE: must be drained to return oil to proper level. Add oil through engine oil fill cap (2, Figure 12), if the oil level is below the "LOW"...

  • Page 142: Check For Leaks In Hydraulic System

    If the level is below "L" mark add oil. Shut down engine. hydraulic tank pressurized. Turn breather cap slowly to allow the pressurized air to vent. Remove the upper cover of the hydraulic tank and add oil. IMPORTANT FG007664 Figure 17 Do not fill above "H"...

  • Page 143: Check Fuel Level

    Check Fuel Level WARNING! extreme safety precautions while refueling prevent explosions or fire. Immediately clean up any split fuel. FG008645 At end of each workday, fill fuel tank. Add fuel through Figure 19 fuel fill tube (1, Figure 19). When working at a temperature of 0°C (32°F) or higher, use ASTM No.

  • Page 144: Check Water Separator And Drain Water As Required

    Check Water Separator and Drain Water as Required Open engine cover and check water separator. When there is water in the cup, a red indicator will close appear in the float window. open FG007667 Figure 21 Turn lever to "CLOSED" position to shut off fuel supply before draining water.

  • Page 145: Check Level Of Window Washer Liquid

    When the engine is cold, remove the radiator cap and check the coolant level inside the radiator. Do not rely on the level of coolant in the coolant recovery tank. Refill radiator required. Refer coolant concentration table. (See page 4-52) Check to make sure that the coolant transfer line from FULL the coolant recovery tank to the radiator is free and...

  • Page 146: Check Air Intake System

    Figure 26 Check the engine intake hose, and hose bands for damage and tightness. If damaged, wrinkled, or loose, replace or retighten or contact your nearest DOOSAN dealer. IMPORTANT Severe engine damage will result from running with unfiltered air. Do not operate engine if any leaks or defects are FG008646 found on air intake system.

  • Page 147: Check The Operation Of All Exterior Lights, Horn And Monitor Lights

    Check the Operation of All Exterior Lights, Horn and Monitor Lights Turn engine starter switch to the "I" (ON) position and observe all the indicator lights. Restore operation of any lightbulbs that do not turn "ON" now. Sound the horn. Repair or replace if required. Turn "ON"...

  • Page 148: 50 Hour / Weekly Service

    50 HOUR / WEEKLY SERVICE Perform All Daily Service Checks Grease Front Attachment Pins Grease every 10 hours for first 100 hours and every 50 hours thereafter. If the unit has been running or working in water the NOTE: front attachment should be greased on a 10 hour / daily basis.

  • Page 149: Grease Dozer Pins And Dozer Cylinder

    Grease Dozer Pins and Dozer Cylinder Dozer pins (2 points). Dozer cylinder (2 points). FG007671 Figure 29 Grease Boom Swing Cylinder and Bracket There are four grease fittings for the Boom Swing. A B C Do not over lubricate, purge oil grease with new. Remove all purged grease.

  • Page 150: Drain Water And Sediment From Fuel Tank

    Drain Water and Sediment from Fuel Tank Perform this procedure before operating the machine. Drain water and sediment from bottom of fuel tank into a suitable container. Dispose of drained fluid according to local NOTE: regulations. Always completely fill fuel tank at end of each NOTE: FG007674 workday to prevent condensation from forming...

  • Page 151: 250 Hour / Monthly Service

    250 HOUR / MONTHLY SERVICE Perform All Daily and 50 Hour Service Checks Clean Outer Filter of Air Cleaner Clean outer filter every 500 hours / 3 months of NOTE: service. When working in severely dusty conditions, the NOTE: service interval should be shortened. WARNING! Never clean or attempt to remove the air cleaner filter if the engine is running.

  • Page 152: Change Engine Oil And Filter

    Clean the outer filter (3, Figure 35) by blowing compressed air from the inside of the filter towards the outside. Do not use more than 205 kPa (30 psi) air pressure. HAOC570L Figure 35 Check outer filter by shinning a light through it. If small holes or thinner parts are found on the element after cleaning it, replace the filter.

  • Page 153: Check Engine Fan Belt Tension

    Replace engine oil filter by using filter wrench. The engine oil filter is a spin-on type. See (1, Figure 38). Remove and discard filter. Install new filter. Apply a small amount of oil around filter gasket. Screw filter on head until gasket contacts head, turn filter 1/2 turn more.

  • Page 154: Check Engine Fan Belt Wear

    Check Engine Fan Belt Wear WARNING! Keep clear of engine fan and fan drive belts when the engine is running. Rotating fan and belt contact can cause injury. WARNING! Figure 40 When checking, adjusting or replacing drive belts, care must be taken to prevent accidental cranking of the engine.

  • Page 155: Check Oil Level In Travel Reduction Device (One On Each Side Of Unit)

    Check Oil Level in Travel Reduction Device (One on Each Side of Unit) WARNING! The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before fully removing any motor case inspection port plug, etc.,...

  • Page 156: Change Hydraulic Oil Suction Filter (After First 250 Hours)

    Change Hydraulic Oil Suction Filter (After First 250 Hours) Change hydraulic suction filter after first 250 hours of NOTE: operation or rebuild, then every 1,000 hours thereafter (See page 4-31). Inspect Pins and Bushings of the Front End Attachments for Signs of Wear Check Fluid Levels in Batteries and Battery Charge Levels Inspect for Any Loose or Missing Nuts...

  • Page 157: 500 Hour / 3 Month Service

    500 HOUR / 3 MONTH SERVICE Perform All Daily, 50 and 250 Hour Service Checks Change Outer and Inner Air Cleaner Elements WARNING! Never clean or attempt to remove the air cleaner element if the engine is running. Change outer element after cleaning 5 times or every NOTE: 2,000 hours of service.
  • Page 158 Change Fuel Filter WARNING! Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. Locate fuel filter inside engine compartment. Position a small container under fuel filter (1, Figure 44). Unscrew fuel filter from head assembly. Discard fuel filter.

  • Page 159: 1,000 Hour / 6 Month Service

    1,000 HOUR / 6 MONTH SERVICE Perform All Daily, 50, 250 and 500 Hour Service Checks Change Hydraulic Oil Return Filter Change hydraulic oil return filter after first 250 hours NOTE: of operation or rebuild, and every 1,000 hours thereafter. WARNING! The hydraulic oil will be hot after normal machine operation.
  • Page 160 Change Oil in Travel Reduction Device (One on Each Side of Unit) WARNING! The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before fully removing any motor case, inspection port plug, etc.,...

  • Page 161: 2,000 Hour / Yearly Service

    2,000 HOUR / YEARLY SERVICE Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks Change Radiator Coolant WARNING! Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to release any remaining pressure.
  • Page 162 Hydraulic oil change interval is 2,000 hours, only when DOOSAN Genuine Oil is used. If another brand of oil is used, guaranteed change interval is 1,000 hours. Based on the type of excavating being completed,...
  • Page 163 Check level using sight gauge on side of tank. Install all parts in reverse order. FG008082 Figure 53 Check Alternator and Starter** **These checks need to be completed by an authorized DOOSAN dealer. Check All Rubber Antivibration Shock Mounts Inspection, Maintenance and Adjustment OP000524 4-35...
  • Page 164 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 Inspection, Maintenance and Adjustment OP000524 4-36...

  • Page 165: Hour / Biennial Service

    4,000 HOUR / BIENNIAL SERVICE Major Parts - Periodic Replacement To ensure safe operation and work, perform periodic inspections. Also, to increase safety, replace the following parts. These parts are the ones most often subjected to abrasion, heat and fatigue. Exchange these parts with new ones at the designated time intervals, even if the old parts look good.

  • Page 166: Hour / Six Year Service

    12,000 HOUR / SIX YEAR SERVICE Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) European regulations state that the in-service life of any DOOSAN hydraulic hose exceed years. recommends the following: • Hoses at the customer premises cannot be stored more than 2 years before being discarded or installed on a machine.

  • Page 167: Bolt And Nut Inspection

    250 hours thereafter. If any are loose or are missing tighten them or install new hardware. Always use a calibrated torque wrench. IMPORTANT Always clean fasteners before tightening. If counterweight is loose, contact a DOOSAN distributor or sales agent. Bolt Bolt TORQUE Point to be Inspected Dia.

  • Page 168: Bucket

    Shut the engine off and lock out the hydraulic controls before working on the bucket. These instructions are only for DOOSAN OEM NOTE: buckets. If you are using other manufacturers buckets, refer to their specific instructions.
  • Page 169 Place bucket, with wooden blocks under it, as shown in illustration. Move front edge of bucket up slightly to make work easier, if desired. Do not raise it too far or the teeth may cause injury if fallen on. Check tooth point side...
  • Page 170 Bucket O-ring Replacement WARNING! Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins. Inspect the bucket O-rings on a routine basis. If worn or damaged, replacement is necessary. Figure 56 Roll the old O-ring (1) onto the bushing (2) around the bucket pin (3).
  • Page 171 Roll the new O-ring (1) into the O-ring groove. FG007697 Figure 59 Inspection, Maintenance and Adjustment OP000524 4-43...
  • Page 172 Bucket Shimming Procedures New Bucket Installation If a new bucket is being installed on excavator, measure inside dimension between bucket ears and outside dimension across arm mounting boss. Subtract clearance on both sides from difference of two and shim accordingly, before assembly. WARNING! To check end play (side to side) clearance at bucket attachment point, the bucket must be free to...
  • Page 173 Replace Bucket WARNING! When removing pin, metal pieces can fly out and cause injury. Be sure to wear safety glasses or goggles, safety hat and safety gloves to prevent injuries. Bucket Disassembly Place bucket as shown in illustration. IMPORTANT In next step, O-rings are removed with pins. Be careful not to damage them.

  • Page 174: Electrical System

    ELECTRICAL SYSTEM Never disassemble electrical or electronic parts. NOTE: Consult with a DOOSAN distributor or sales agency before servicing. Battery WARNING! Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water.
  • Page 175 Inspection of Battery Electrolyte Level This machine has two maintenance free batteries. They never require the addition to water. When the charge indicator becomes transparency, it means low electrolyte state because of the leakage or charging system error. Determine the cause of problem and replace the batteries immediately.
  • Page 176 Fuse Box There is a fuse box (Figure 65) in the electric box which is under the seat. The fuses prevent electrical devices from overloading or shorting. A decal attached to 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.

  • Page 177: Engine Cooling System

    ENGINE COOLING SYSTEM General Keeping an engine's cooling system in peak operating condition can have many benefits in keeping a machine in good operating condition. A properly functioning cooling system will; improve fuel efficiency, reduce engine wear, and extend component life. Always use distilled water in the radiator.
  • Page 178 WARNING! Pressure at air nozzle must not exceed 2.1 kg/cm psi). Always wear goggles when using compressed air. Do not pour cold water into radiator when engine is very hot and water level is below the top of the tubes. Such action could result in damage to engine cylinder heads.
  • Page 179 Check antifreeze concentration levels comparing the color change at the end of test paper, with the green spectrum range, with the green symbol upper portion container bottle. A suitable concentration indicator should NOTE: be between 33% and 50%). Check the anticorrosive additives, by comparing brown color in the middle range of the test strip and pink color on the lower part of the test strip, with the brown and pink spectrum range.
  • Page 180 (extended life antifreeze) does. Ethylene glycol is also very hazardous to the environment, people and animals. DOOSAN recommends that ethylene glycol be replaced with propylene glycol. The newer propylene glycol antifreeze comes in many different colors.

  • Page 181: Handling Of Accumulator

    DO NOT weld on accumulator, or try attaching anything to it. • When replacing an accumulator, contact a DOOSAN distributor or sales agency so the gas can be properly released. • Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under pressure can penetrate the skin and cause serious injuries.

  • Page 182: Long Term Storage

    LONG TERM STORAGE IMPORTANT When storing machine, position as shown in illustration to protect the cylinder rod. Protect the cylinder against rust. Perform the following if storing the excavator for more than one month. FG007662 Figure 69 Conditions Maintenance Required Cleaning Pressure wash the undercarriage and wheel drive assemblies.

  • Page 183: Maintenance In Special Conditions

    MAINTENANCE IN SPECIAL CONDITIONS See “Operation Under Unusual Conditions” on NOTE: page 3-39 for other recommendations. Conditions Maintenance Required Operating in mud, water or rain. Perform a walk around inspection to check for any loose fittings, obvious damage to the machine or any fluid leakage.

  • Page 184: Track Tension

    TRACK TENSION WARNING! Safely measuring track tension requires two people. One person must be in the operator's seat, running the controls to keep one side frame in the air, while the other person makes dimensional checks. Take necessary precautions to make sure the machine won't move or shift position during service.
  • Page 185 For machines with steel crawlers (optional), NOTE: checking adjustment steps clearance are the same. Figure 72 WARNING! track adjusting mechanism under very high-pressure. NEVER release pressure suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from the fully tightened down position.

  • Page 186: Venting And Priming Hydraulic System

    VENTING AND PRIMING HYDRAULIC SYSTEM Main System Pump If pump is run without sufficient oil in the main NOTE: hydraulic pump, damage can occur. Always vent pump of air after draining hydraulic system. With the engine stopped, remove vent plug (Figure 76) to see if any oil is present.
  • Page 187 Travel Motor Perform this only when oil is drained from travel NOTE: motor Shut down engine Disconnect drain hose (Figure 77) and fill motor case with hydraulic oil. Connect drain hose. Start engine and set engine speed control dial to "LOW FG007712 IDLE."...
  • Page 188 Inspection, Maintenance and Adjustment OP000524 4-60...

  • Page 189: Transportation

    OP000525 Transportation Obey local, state federal regulations transportation of the excavator. If unsure of regulations check with local authorities. Check intended route road width, overhead clearances, weight restrictions, and traffic control regulations. Special approval or permits may be required. LOADING AND UNLOADING WARNING! When transporting the machine, know the width, height, length and weight.
  • Page 190 Make sure that the trailer is parked on firm, level ground. See Figure 1. Make sure that the ramps that are being used are designed to handle the weight of the excavator. If 90 ~ 110 required, add blocking under the ramp to provide additional support.
  • Page 191 Set safety lever on "LOCK" position. Lock Unlock FG007566 Figure 5 Shut down engine by turning key to "O" (OFF) position (Figure 6). 10. Remove key from starter switch. FG001364 Figure 6 11. Make sure to secure the excavator onto the trailer before transporting.

  • Page 192: Lifting With Sling

    LIFTING WITH SLING WARNING! Improper lifting can allow load to shift and cause injury or damage. Refer to “Specification” on page 7-1 of this manual for information on weight and dimensions. Use properly rated cables and slings for lifting. Position machine for a level lift. Lifting cables should have a long enough length to prevent contact with the machine.

  • Page 193: Troubleshooting

    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.

  • Page 194: Relief Valve

    Problem Possible Cause Remedy Leaky oil seal. Foreign material in spool. Clean or replace valve housing assembly. Pressure too high. Check with pressure gauge and adjust. Lever or linkage bent. Remove and check linkage. Return spring damaged. Replace. Valve temperature uneven. Warm up entire system.

  • Page 195: Control Lever

    CONTROL LEVER Problem Possible Cause Remedy Lever feels "heavy" when Foreign material in control valve Clean control valve. operated. spool. Valve spool sticking. Replace valve housing assembly. Lack of linkage lubrication. Lubricate. ATTACHMENTS Problem Possible Cause Remedy Lack of power. Lack of engine power.

  • Page 196: Hydraulic Motor

    HYDRAULIC MOTOR Problem Possible Cause Remedy Hydraulic motor does not Hydraulic oil low. Add oil. rotate. Hydraulic pump bad. Replace pump. Oil leak from inside hydraulic Replace motor. motor. Overload applied to output shaft. Locate and remove cause of overload. Low viscosity hydraulic oil.

  • Page 197: Hydraulic Pump

    HYDRAULIC PUMP Problem Possible Cause Remedy Poor oil delivery. Hydraulic oil level low. Add oil. Suction filter restricted. Clean or replace filter. Pressure does not rise. Oil leak from inside pump. Replace pump. Air in pump. Add oil or check suction side hose. Main relief valve pressure set too Adjust pressure.

  • Page 198: Travel

    TRAVEL Problem Possible Cause Remedy Lack of power when Main relief valve pressure set too Adjust pressure. traveling. low. Counterbalance valve bad. Replace counterbalance valve. Hydraulic motor performs poorly. Replace hydraulic motor. Damaged center joint seal. Replace seal. Hydraulic pump bad. Replace hydraulic pump.

  • Page 199: Specification

    OP000473 Specification STANDARD SPECIFICATION SPECIFICATION COMPONENT STANDARD 1.1 m 1.3 m 1.3 m ARM (1.1 m ARM) ARM+Q/C ARM+Q/C Bucket SAE (CECE) 0.08 m (0.07 capacity Operating weight 2.71 tons Engine Model 3TNV82A-SDB Displacement 1,331 cc (Total dis. Volume) 22.1 hp @ 2,200 rpm Rated power 16.5 kW @ 2,200 rpm Front...

  • Page 200: Overall Dimensions

    OVERALL DIMENSIONS FG007625 Figure 1 Specification OP000473...
  • Page 201 DIMENSION 2.0 m (6.56 ft) BOOM 4,043 mm (13' 3") 960 mm (3' 2") 760 mm (2' 6") 3,083 mm (10' 1") 1,488 mm (4' 11") 355 mm (1' 2") 340 mm (1' 1") 1,451 mm (4' 9") 1,550 mm (5' 10") 1,970 mm (6' 6") 2,411 mm (7' 11") 520 mm (1' 8")

  • Page 202: Working Range

    WORKING RANGE FG008834 Figure 2 2.0 m (6.56 ft) BOOM DIM. 1.1 m (3.6 ft) ARM 1.3 m (4.26 ft) ARM Max. digging radius 4,504 mm (14' 9") 4,690 mm (15' 5") Max. vertical digging depth 2,058 mm (6' 9") 2,250 mm (7' 5") Max.

  • Page 203: Approximate Weight Of Workload Materials

    APPROXIMATE WEIGHT OF WORKLOAD MATERIALS IMPORTANT Weights approximations estimated average volume and mass. Exposure to rain, snow or ground water; settling or compaction due to overhead weight and chemical or industrial processing or changes due to thermal or chemical transformations could all increase value of weights listed in table.
  • Page 204 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS 961 kg/m Gypsum, calcined, (heated, powder) --------------------- --------------------- (1,620 lb/yd...

  • Page 205: Index

    Index Numerics 4-31 1,000 Hour / 6 Month Service Description of Lubrication and Service Chart 4-12 2-27 10 Hour / Daily Service Door Side Latch 4-38 12,000 Hour / Six Year Service 4-33 2,000 Hour / Yearly Service 4-23 250 Hour / Monthly Service 4-46 Electrical System 4-37...
  • Page 206 4-59 3-37 General Venting Lifting 4-20 Grease Front Attachment Pins Lifting With Sling Lights 2-20 Cabin Loading and Unloading Handling a New Excavator Locations of Safety Labels 4-53 Handling of Accumulator 4-54 Long Term Storage 2-28 Hanger Lubrication and filters 4-36 Head Bolt Torques Lubrication and Service Chart...
  • Page 207 Relief Valve Starter Switch 3-14 Travel Speed Control Travel Speed Selector Switch 2-10 Warnin Light Safety 2-11 Windshield Washer 3-13 Safety Lever 2-11 Wiper Safety Precautions Work Light Switch 2-23 Seat Seat Adjustment 2-23 Adjusting the Seat Forward 2-23 Adjusting the Seat's Angle Table of Recommended Lubricants 2-23, 4-18 3-29...

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