Doosan DX700LC Operation And Maintenance Manual
  1. Manuals
  2. Brands
  3. Doosan Manuals
  4. Excavators
  5. DX700LC
  6. Operation and maintenance manual

Doosan DX700LC Operation And Maintenance Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
DX700LC
Operation and Maintenance Manual
950106-00012E
Serial Number 5001 and Up
June 2010
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product
to the market place. These improvements can be implemented at any time with no obligation to change materials
on previously sold products. It is recommended 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 equipment, and
may vary from the actual item.
950106-00012E Operation and Maintenance Manual
Copyright Doosan 2010

Advertisement

Table of Contents
loading

Related Manuals for Doosan DX700LC

Summary of Contents for Doosan DX700LC

  • Page 1 Serial Number 5001 and Up June 2010 DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.

  • Page 3: Table Of Contents

    Table of Contents Safety ..................1-1 To the Operator of a DOOSAN Excavator ......... 1-1 Location of Safety Labels..............1-4 Summary of Safety Precautions for Lifting in Digging Mode.... 1-15 Unauthorized Modifications.............. 1-16 General Hazard Information............. 1-16 Before Starting Engine..............1-25 Machine Operation................
  • Page 4 Ceiling Cover ................... 2-62 Front Windows ................. 2-63 Door Side Latch ................2-65 Cabin Storage Compartments ............2-66 Ashtray..................... 2-66 Sun Visor ..................2-67 Hanger ..................... 2-67 Cup Holder..................2-68 Door Window Holder................ 2-68 Emergency Glass Breaking Tool ............. 2-68 Miscellaneous Access Covers and Doors........
  • Page 5 10 Hour / Daily Service ..............4-14 50 Hour / Weekly Service ..............4-25 250 Hour / Monthly Service.............. 4-28 500 Hour / 3 Month Service ............. 4-34 1,000 Hour / 6 Month Service ............4-43 2,000 Hour / Yearly Service ............. 4-49 4,000 Hour / Biennial Service ............
  • Page 6 Specification ................7-1 Approximate Weight of Workload Materials........7-6 Index ...................8-1 Table of Contents 950106-00012E...

  • Page 7: Safety

    OP001120 Safety TO THE OPERATOR OF A DOOSAN EXCAVATOR DANGER Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and 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 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...
  • Page 9 Safety precautions are described in SAFETY from page 1-4 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions.

  • Page 10: Location Of Safety Labels

    LOCATION OF SAFETY LABELS FG016159 Figure 1 Safety OP001120...
  • Page 11 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 of the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words.
  • 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 arm.
  • Page 13 3. Warnings When Opening a Front Window (2190-3388, 190-00093) When raising window, lock it in place with lock pins on both sides. Falling window can cause injury. 2190-3388 190-00093 FG000665 4. Warnings for a High-pressure Cylinder (190-00122) 190-00122 ARO1110L Safety OP001120...
  • Page 14 5. Warnings When Adjusting Track Tension (2190-3386A, 190-00521) T h e t r a ck a d j u s t e r a d j u s t m e n t a n d h a n d l i n g The spring in the track adjuster is loaded with great force and the pressure in the cylinder is very high.
  • Page 15 7. Warnings for Batteries Maintenance (2190-2533A, 190-00100) Battery fumes can explode. Keep sparks and flames away from batteries. Always avoid storing metals like tools or flammable materials around or on the batteries. Explosion or fire can be caused by shortcircuiting batteries. Surfuric acid in battery is poisonous.
  • Page 16 9. Warnings for Hot Coolant (190-00692, 190-00097) 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 190-00097 slowly to relieve the pressure.
  • Page 17 11. Warnings for Rotating Parts (190-00694, 190-00095, 190-00557) 190-00095 Rotating par ts can cause personal injur y. Keep away from fan and belt when engine is run- ning. Stop engine before ser vicing. 190-00557 190-00694 ARO1190L 12. Warning Tag - Used When Inspection and Maintenance (190-00695A, 190-00098A) WARNING...
  • Page 18 13. Warning for a Hot Surface (190-00648A) 190-00648 ARO1210L 14. Caution for Hood (190-00522A) 190-00522A FG012965 15. Keep Out of the Swing Area (2190-3379A, K1008571) 2190-3379A K1008571 FG006551 Safety OP001120 1-12...
  • Page 19 16. Warnings for Front Attachments (190-00652) 190-00652 ARO1230L 17. Warning for Engine ECU (K1012583) CAUTION To prevent damage to ECU of engine by electrical welding to the body structure. Be sure to read the procedures described in the Operation and Maintenance manual carefully before electrical welding.
  • Page 20 18. Warning for Lifting, Tie Down (K1042074A) K1042074A FG014828 19. Warning for Tie Down (950209-00205) 950209-00205 FG014875 Safety OP001120 1-14...

  • Page 21: Summary Of Safety Precautions For Lifting In Digging Mode

    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 environment, please consult your local DOOSAN representative. Safety OP001120 1-15...

  • Page 22: Unauthorized Modifications

    UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner must be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking...
  • Page 23 Inside Operator's Compartment When entering the operator's compartment, 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 24 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 25 Keep the terrain on work sites where the machine is working and traveling in good condition. • Remove any large rocks or obstacles. • Fill any ditches and holes. • Provide machines for and schedule time to maintain the terrain conditions. Travel over longer distance (e.g.
  • Page 26 Fuel, Oil and Hydraulic Fluid Fire Hazards Fuel, oil and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area.
  • Page 27 Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your health if it is inhaled. Materials containing asbestos fiber can be present on work site. Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage. To prevent lung damage from asbestos fiber, observe following precautions;...
  • Page 28 Reinstallation, recertification and/or replacement of the system may be necessary. Contact your DOOSAN distributor for available safety guards and/or recommendations if there is any 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 29 Attachment Precautions Option kits are available through your dealer. Contact DOOSAN for information on available one-way (single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DOOSAN cannot anticipate, identify or test all of the attachments that owners may wish to install on their machines, please contact DOOSAN for authorization and approval of attachments, and their compatibility with options kits.
  • Page 30 Emergency Exit This machine is equipped with a glass breaking tool. It is behind the operator seat in the upper right corner of the cabin. This tool can be used in case of an emergency situation that requires the breaking of glass to exit from the operator's cabin. Grip the handle firmly and use the sharp point to break the glass.

  • Page 31: 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 the ground surface as hard and horizontal as possible before carrying out operations.
  • Page 32 Checks Before Starting Engine Every day before starting the engine for the first time, carry out the following checks. If these checks are not carried out properly, there is danger of serious injury. Completely remove all wood chips, leaves, grass, paper and other flammable materials accumulated in the engine compartment and around the battery.
  • Page 33 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 34: 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 the direction of travel from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing the HAOA190L...
  • Page 35 Travel Precautions Travel Posture Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops when the machine is traveling. It will be impossible to operate the steering. Attachment control levers should not be operated while traveling.
  • Page 36 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 37 Prohibited Operations Do not dig the work face under an overhang. This may cause the overhang to collapse and fall on top of the machine. FG015755 Figure 20 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.
  • Page 38 Precautions for Operation Be careful not to go close to the edge of a cliff by mistake. Use the machine only for its main purpose. Using it for other purposes will cause failures. To ensure an ample view, do as follows: •...
  • Page 39 Protecting Cabin from Falling Object (Optional) In a work site where falling objects or flying objects are expected, be sure to install adequate protective devices for covering the cabin. When using a breaker, be sure to install the front window protection guard (Figure 25).
  • Page 40 Operations on Slopes When working on slopes. there is danger that the machine may lose its balance and turn over, when swinging, or when work equipment is operated. Always carry out these operations carefully. Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded.

  • Page 41: Maintenance

    OSHA certified lockout device and a length of chain or cable to keep the safety lever in the fully when performing inspection lowered, nonactive position. Warning tags, for controls are available from DOOSAN 190-00695A distributors. FG012195...
  • Page 42 Proper Tools Use only tools suited to the task. Using damaged, low qualify, 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 32 Use of Lighting...
  • Page 43 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. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
  • Page 44 Welding Repairs CAUTION When you connect or disconnect connectors between ECU and Engine or connector between ECU and the machine, always disconnect the source power to protect damage of the ECU. If you don't observe this procedure, the ECU would be damaged or the engine would operate abnormally.
  • Page 45 Warning for Counterweight and Front Attachment Removal DANGER DOOSAN warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
  • Page 46 Precautions for Removal, Installation, and Storage of Attachments Before starting removal and installation of attachments, decide the team leader. Do not allow anyone except the authorized workers close to the machine or attachment. Place attachments that have been removed from the machine in a safe place so that they do not fall.
  • Page 47 Crushing Prevention and Cutting Prevention You should always have at least two people working together if the engine must be run during service. One person needs to remain in the operator's seat, ready to work the controls or stop the machine and shut off the engine. Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.
  • Page 48 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 that the pressure has been released from the circuit.
  • Page 49 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 50: 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 51 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 52: Towing

    • 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 • Never go between the towing machine and the towed FG014876 machine during the towing operation.

  • Page 53: 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 54: 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 55 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 and procedures within this Operation and Maintenance Manual.
  • Page 56 Track Width : 4.0 m (13' 1") Track Boom : 7.7 m (25' 3") : 3.55 m (11' 8") Bucket : SAE 3.3 m (4.3 yd : 650 mm (2' 2") Shoe : 8,500 kg (18,700 Ib) Counter Weight : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb)
  • Page 57 FEET A(ft) B(ft) 25.02 * 25.02 * 29.50 * 29.50 * 26.17 * 25.2 56.84 * 56.84 * 40.86 * FALSE 32.76 * 32.76 * 27.93 * 24.05 46.74 * 44.45 36.07 * 31.08 29.80 * 22.82 50.76 * 41.55 38.67 * 29.3 31.32 *...
  • Page 58 Track Width : 4.0 m (13' 1") Track Boom : 7.7 m (25' 3") : 2.9 m (9' 6") Bucket : SAE 3.3 m (4.3 yd : 650 mm (2' 2") Shoe Counter Weight : 8,500 kg (18,700 Ib) : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb)
  • Page 59 FEET A(ft) B(ft) 26.09 * 25.01 30.68 * 30.68 * 26.97 * 24.32 42.54 * 42.54 * 33.68 * 32.13 28.49 * 23.23 47.78 * 42.72 36.62 * 30.03 30.09 * 22.06 50.81 * 40.11 38.72 * 28.37 31.26 * 21.06 60.08 * 60.08 *...
  • Page 60 Track Width : 4.0 m (13' 1") Track Boom : 7.7 m (25' 3") : 4.2 m (13' 9") Bucket : SAE 3.0 m (3.9 yd : 650 mm (2' 2") Shoe : 8,500 kg (18,700 Ib) Counter Weight : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb)
  • Page 61 FEET A(ft) B(ft) 30.67 * 30.67 * 44.11 * 44.11 * 34.33 * 31.74 64.97 * 64.97 * 49.09 * 42.42 37.43 * 29.75 65.64 * 64.94 51.63 * 40.34 39.35 * 28.31 50.37 * 50.37 * 70.39 * 64.34 51.61 * 39.37 39.69 *...
  • Page 62 Track Width : 4.0 m (13' 1") Track Boom : 6.65 m (21' 10") : 2.9 m (9' 6") Bucket : SAE 3.9 m (5.1 yd : 650 mm (2' 2") Shoe Counter Weight : 8,500 kg (18,700 Ib) : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb)
  • Page 63 Track Width : 4.0 m (13' 1") Track Boom : 6.65 m (21' 10") : 2.6 m (8' 6") Bucket : SAE 4.5 m (5.89 yd : 650 mm (2' 2") Shoe Counter Weight : 8,500 kg (18,700 Ib) : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb)
  • Page 64 Track Width : 4.0 m (13' 1") Track Boom : 7.7 m (25' 3") : 3.55 m (11' 8") W/O Bucket : 900 mm (2' 11") Shoe : 11,300 kg (24,900 Ib) Counter Weight : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb) FG016166...
  • Page 65 FEET A(ft) B(ft) 31.28 * 30.02 35.94 * 35.94 * 32.29 * 29.38 48.30 * 48.30 * 39.26 * 37.58 33.99 * 28.42 54.16 * 49.36 42.55 * 35.78 35.79 * 27.4 57.70 * 47.08 44.94 * 34.33 37.15 * 26.51 58.34 * 45.94...
  • Page 66 Track Width : 4.0 m (13' 1") Track Boom : 7.7 m (25' 3") : 2.9 m (9' 6") W/O Bucket : 900 mm (2' 11") Shoe : 11,300 kg (24,900 Ib) Counter Weight : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb) FG016167...
  • Page 67 FEET A(ft) B(ft) 35.20 * 35.20 * 35.70 * 35.70 * 33.56 * 29.32 44.94 * 44.94 * 37.94 * 37.94 * 33.96 * 28.88 51.00 * 51.00 * 40.96 * 36.85 35.30 * 28.01 43.81 * 35.17 36.73 * 27.08 58.36 * 46.36...
  • Page 68 Track Width : 4.0 m (13' 1") Track Boom : 7.7 m (25' 3") : 4.2 m (13' 9") W/O Bucket : 900 mm (2' 11") Shoe : 11,300 kg (24,900 Ib) Counter Weight : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb) FG016168...
  • Page 69 FEET A(ft) B(ft) 28.82 * 28.82 * 28.97 * 28.97 * 30.28 * 29.67 44.87 * 44.87 * 36.96 * 36.96 * 32.22 * 28.61 51.29 * 50.17 40.59 * 36.08 34.30 * 27.47 55.88 * 47.41 43.52 * 34.4 36.04 * 26.44 57.77 *...
  • Page 70 Track Width : 4.0 m (13' 1") Track Boom : 6.65 m (21' 10") : 2.9 m (9' 6") W/O Bucket : 900 mm (2' 11") Shoe : 11,300 kg (24,900 Ib) Counter Weight : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb) FG016169...
  • Page 71 Track Width : 4.0 m (13' 1") Track Boom : 6.65 m (21' 10") : 2.6 m (8' 6") W/O Bucket : 900 mm (2' 11") Shoe : 11,300 kg (24,900 Ib) Counter Weight : Rating Over Front : Rating Over Side or 360 degree Unit : 1,000 kg (1,000 lb) FG016170...
  • Page 72 Safety OP001120 1-66...

  • Page 73: Operating Controls

    OP001121 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 2-20 “Multifunction Gauge Graphic Information” page 2-27 “Mode Selector Buttons”...

  • Page 74: Component Locations

    COMPONENT LOCATIONS FG015770 Figure 1 Operating Controls OP001121...
  • Page 75 Reference Reference Description Description Number Number Arm Cylinder Track Link and Shoe Boom Track Guard Boom Cylinder Upper Roller Fuel Tank Fill Cap Lower Roller Fuel Tank Cabin Swing Motor Track Adjuster Oil Cooler Work Lever Controls (Joystick) Air Cleaner Seat Control Valves Center Joint...

  • Page 76: Operator's Area

    OPERATOR'S AREA FG013745 Figure 2 Operating Controls OP001121...
  • Page 77 Reference Reference Description Description Number Number Instrument Panel Storage Compartment (See page 2-20) (See page 2-66) Cigarette Lighter Heater and Air Conditioner Unit (See page 2-14) Stereo Ashtray (See page 2-55) (See page 2-66) Fuse Box Travel Levers (See page 2-57) (See page 3-15) Left-hand Work Lever (Joystick) Right-hand Work Lever...

  • Page 78: Operational Controls And Panels

    OPERATIONAL CONTROLS AND PANELS 16 27 12 11 10 9 8 FG015771 Figure 3 Operating Controls OP001121...
  • Page 79 Reference Reference Description Description Number Number Starter Switch Power Socket For 12v Engine Speed Control Dial Travel / Swing Alarm Switch (Optional) Quick Clamp Switch (Optional) Overload Warning Switch Auxiliary Mode Switch (Optional) Engine Emergency Stop Switch Fuel Heater Switch (Optional) Audio Control Panel Seat Warmer Switch (Optional) Travel Speed Selector Switch...
  • Page 80 1. Starter Switch A three-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 and fuel tank transfer pump (if equipped) are functional.
  • Page 81 3. Quick Clamp Switch (Optional) Clamp releasing for dispensable attachment is controlled. In this position , the quick clamp is "LOCKED". The attachment is secured to the arm. In this position , the quick clamp is "UNLOCKED". The attachment is released from the arm. NOTE: To move the switch, pull up on the toggle and then move it into the "UNLOCKED"...
  • Page 82 6. Audio Control Panel The audio system can be remotely controlled using this panel. SCAN FG000018 Figure 9 Each 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".
  • Page 83 Manual Scan: When pressing scan button once, for less than half-a-second, the frequency will be moved up in sequence to the next available signal. Auto Scan: When pressing scan button for more than a half-a-second, the frequencies are automatically scanned to the next higher one and will continue until the button is SCAN again pressed to stop the scan.
  • Page 84 9. Breaker / Boost / Shear Selector Switch This switch is used to either select the breaker, power boost, or shear. In this position, a hydraulic pressure rise will be activated when pressing the button on the right-hand work lever (joystick). In this position, shear is activated.
  • Page 85 12. Lower Wiper Switch (Optional) This switch is used to control the lower front window wiper. In this position, lower windshield wiper is "OFF". In this position, lower windshield wiper runs at a constant speed. NOTE: Operating wiper without washer fluid or when there is sand or dirt present will damage the window and wiper.
  • Page 86 Intermittent Speed Button Pressing button once (first time): Windshield wiper runs approximately on a three second intermittent cycle. The left side indicator light will turn "ON". Pressing button again (second time): Windshield wiper runs approximately on a six second intermittent cycle. The right side indicator light will turn "ON".
  • Page 87 16. Power Socket for 12 Volt This is a power socket for only 12V DC devices. This socket can be used for charging a cellular phone or powering a small 12V DC electrical device. Open the cap when using it. 12 V NOTE: This socket is designed for small electrical...
  • Page 88 19. Fuel Heater Switch (Optional) This switch is used to activate the fuel heater system. When the switch is activated, the fuel is warmed, depending upon the temperature of the fuel. NOTE: If the fuel temperature is above 5°C (41°F), heating system is not activated.
  • Page 89 22. Rotating Buttons For a machine equipped with an attachment that rotates, press the upper two buttons on the top of the left-hand work lever (joystick) to rotate the attachment clockwise or counterclockwise. Left button is for counterclockwise and the right one is for clockwise. WARNING FG000382 Before using any attachment in a work application, be...
  • Page 90 25. Instrument Panel See “Instrument Panel” on page 2-20. FG013662 Figure 35 26. Safety Lever See “Safety Lever” on page 3-13. FG000038 Figure 36 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.
  • Page 91 28. Liftting mode switch This switch is used to work the liftting pipes or heams. In this position, "STD" work mode is selected. In this position, "Liftting" working moce is selected. FG015772 Figure 38 29. Manual Operating Switch of Auto Greasing Device This switch is used to operate the auto greasing device manually.

  • Page 92: Instrument Panel

    INSTRUMENT PANEL CHECK < CONNECTOR AND TERMINAL NO.> AMP 040 28P (CN7) (CN6) FG013521 Figure 40 Operating Controls OP001121 2-20...
  • Page 93 Reference Reference Description Description Number Number Fuel Gauge Power Mode Selector Button (See page 2-33) Engine Coolant Temperature Gauge Economy Mode Selector Button (See page 2-33) Hydraulic Oil Temperature Gauge Auto Idle Selector Button (See page 2-34) Multifunction Gauge And Graphic Information Area (See page Flow Control Button 2-27)
  • Page 94 1. Fuel Gauge Shows remaining fuel quantity in tank. BLUE ZONE ( ) - Indicates a normal fuel quantity. RED ZONE ( ) - Indicates that the fuel level is low. If the gauge pointer moves into the red zone, the fuel level symbol will turn "ON", and be display in the screen.
  • Page 95 3. Hydraulic Oil Temperature Gauge The colored bands indicate the temperature of the hydraulic oil WHITE ZONE ( ) - Indicates temperature is lower than the normal operating temperature. BLUE ZONE ( ) - Indicates temperature is within the normal operating range. RED ZONE ( ) - Indicates temperature is too high.
  • Page 96 6. 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. HAOA601L Figure 46 7.
  • Page 97 9. Engine Coolant Temperature Warning Light If engine coolant overheats, this light will turn "ON", an alarm will sound, and the engine speed will be automatically reduced, until coolant temperature drops. Do not turn engine "OFF" because this will cause coolant temperature to rise and may cause engine to siege due to heat surge.
  • Page 98 11. Preheating Indicator Light In cold weather this light indicates that the engine preheat function is operating. When this indicator light turns "OFF", it means that the engine preheat cycle has been completed. HAAE2000 Figure 51 12. Work Light Indicator Light The indicator light indicates that the work lights are turned "ON".

  • Page 99: Multifunction Gauge And Graphic Information

    MULTIFUNCTION GAUGE AND GRAPHIC INFORMATION When the engine starter switch is turned to the "I" (ON) position, a LOGO will appear on the display screen for about two seconds. When the LOGO disappears, the multifunction gauge and graphic information screen will appear. The engine rpm is normally displayed at the bottom of the screen when the starter switch is first turned "ON".
  • Page 100 Communication Error Warning If a communication error is generated between e-EPOS controller and instrument panel, this symbol will be displayed. When this symbol is displayed, contact a DOOSAN distributor or sales agency. NOTE: If a communication error occurs during operation, the last mode setting is stored.
  • Page 101 Front Hydraulic Pump Pressure The front pump pressure is numerically displayed. NOTE: This pump is closest to engine flywheel housing or is the upper one of hydraulic pump. FRONT PUMP It displays the reading in bars. FG000051 Figure 58 Rear Hydraulic Pump Pressure The rear pump pressure is numerically displayed.
  • Page 102 Examples of Warning Display FG013705 FG013703 FG013704 <2 kinds of warning display> <4 kinds of warning display> <7 kinds of warning display> Figure 61 Hydraulic Oil Overheat Warning If the hydraulic oil temperature is too high, this symbol appears on the screen. FG000056 Figure 62 Pilot Filter Clogged Warning...
  • Page 103 Fuel Shortage Warning If the fuel quantity is too low, this symbol appears on the screen. If this light turns "ON", add fuel as soon as possible. FG000057 Figure 64 Return Filter Clogged Warning This symbol indicates when the hydraulic return filter is clogged.
  • Page 104 Overload Warning (Optional) If the overload warning switch is turned "ON", and this symbol appears on the screen and the warning buzzer sounds, that indicates that overloaded condition is occurring. Immediately reduce the load. WARNING If this warning appears on the screen and a warning FG000253 buzzer sound, reduce the load immediately.

  • Page 105: Mode Selector Buttons

    MODE SELECTOR BUTTONS Power Mode Selector Button Trenching Mode Selector Button Auto Idle Selector Button Flow Control Button FG013707 Figure 69 1. Power Mode Selector Button This power mode is suitable for heavy-duty work that requires a high operating speed. Push this button to turn power mode "ON"...
  • Page 106 3. Auto Idle Selector Button When the auto idle system is activated, the engine will automatically reduce speed to "IDLE" approximately four seconds after all of the control levers are in the neutral position. This system is designed to reduce fuel consumption and noise.

  • Page 107: Setting Main Menu

    SETTING MAIN MENU By using a combination of the selector buttons (Figure 75), you can review and set 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. FG013591 Figure 74 FG013712...
  • Page 108 2. Down Arrow Button Down arrow button ( ), is used to move a menu item "Down" or to the "Right". FG000069 Figure 77 3. Display Selector Button (ESC - Escape) Display selector button ( ), is used to change the displayed information on the screen.
  • Page 109 Display Selection and Escaping Display Selection When the display button (Figure 81) is pressed for more than three seconds, the main menu screen (Figure 83) is displayed. In the normal display screen, the engine speed (rpm), battery voltage (volt), front pump pressure (bar), and rear pump pressure (bar) can be displayed.
  • Page 110 Language Languag When the cursor is on "Language", press the "SELECT" ( button. The language submenu will appear. 1. Korean 2. English The desired language can be selected by using the "UP" ( ) or "DOWN"( ) buttons. The display can be set for the desired language. Press the "SELECT"...
  • Page 111 '00' Minute Setting SET CLOCK Simultaneously press the "SELECT" ( ) button and "UP" ) button. 02:30:30 If the displayed time is 30 minutes or less, the clock will 2003 11/04 display the preceding hour. If the displayed time is more than 30 minutes, the clock will display the succeeding hour.
  • Page 112 Menu Display Order and Icon Explanation 1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Hyd. Oil Filter 5. Pilot Filter 6. Engine Oil 7. Hydraulic Oil 8. Coolant Water FG001358 Figure 90 Filter / Oils Operating Hour Reset Filter/Oil Information After changing a filter or oil, reset the operating hour to zero (Hrs: 0000).
  • Page 113 Adjust Display MAIN MENU When the cursor is on "Adjust Display", press the "SELECT" 1. Language ) button. The adjust display submenu will appear. 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password : UP : DOWN : SELECT FG013569...
  • Page 114 Set Password (Lock and Unlock) Use extreme care when setting the password for starting the engine. If a mistake is made when entering the number, and the number is excepted by the system, as being correct, that number will be the only one that will allow the security system to be activated or deactivated.
  • Page 115 : DOWN : SELECT Select adoption (lock) or non-adoption (unlock) at set FG013718 password menu. Figure 98 NOTE: Keep in mind never to forget password. NOTE: Please contact a DOOSAN distributor, if you forget your password. Operating Controls OP001121 2-43...

  • Page 116: Flow Control

    FLOW CONTROL The flow control is used to set the proper flow rate for an optional attachment (If equipped). The flow control screen is accessed directly from the normal display screen without going through the main menu or any submenus. FG013591 Figure 99 When the flow control button (Figure 73 and Figure 100) is...
  • Page 117 Adjusting Flow Rate FLOW CONTROL Use "UP" ( ) or "DOWN" ( ) buttons to adjust flow rate. "UP" ( ) button is used to increase a flow rate. "DOWN" ( ) button is used to decrease a flow rate. Flow Control Step Pump Flow Setting (l/min) : APPLY...

  • Page 118: Operation Selection Display

    OPERATION SELECTION DISPLAY In the monitor you can see the application that is currently selected. Power Mode Selection FG013720 Figure 105 Standard Mode Selection FG013721 Figure 106 Economy Mode Selection FG013722 Figure 107 Operating Controls OP001121 2-46...
  • Page 119 Auto Idle Selection AUTO FG013723 Figure 108 Power Boost Selection FG013724 Figure 109 Breaker Selection FG013725 Figure 110 Shear Selection FG013726 Figure 111 Operating Controls OP001121 2-47...
  • Page 120 Quick Clamp Operation Selection (Optional) FG013728 Figure 112 Camera Mode Selector Button Camera mode selector button (optional) Push 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.

  • Page 121: Heater And Air Conditioner Control Panel

    HEATER AND AIR CONDITIONER CONTROL PANEL Location of Controls and Vents FG013837 Figure 114 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.
  • Page 122 Control Panel OUTSIDE AUTO AUTO TEMP MODE FG000086 Figure 115 Reference Reference Description Description Number Number Automatic Temperature Control Air Inlet Selector Button Button Fan Speed Selector Button Off Button Air Conditioner Button Temperature Control Button Defroster Button Temperature Unit Selector LCD Display Button Air Outlet Selector Button...
  • Page 123 Off Button This button is used to stop the fan and air conditioner. FG000089 Figure 117 Temperature Control Button These buttons are used to control the cabin temperature. 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.
  • Page 124 Mode Selector Button This button is used to select which combination air outlets will be used. MODE FG000096 Figure 120 Used to direct air flow to upper portion of operator's cabin from both the front and rear. FG000099 Figure 121 Used to direct air flow to upper portion of operator's cabin from both the front and rear.
  • Page 125 Used to direct air flow to the front window and to operator's feet. FG000098 Figure 124 Air Inlet Selector Button This button is used to select fresh air from outside the cabin, or recirculate air within the cabin. Pressing this switch enables the choice between fresh air and recirculating air within the operator's compartment.
  • Page 126 Air Conditioner Button This button is used to turn the air conditioner "ON" or "OFF". When this function is activated, an "A/C" is displayed in the upper left corner of the LCD. FG000105 Figure 128 Defroster Button Used to direct air flow to front window. FG000106 Figure 129 10.

  • Page 127: Stereo

    STEREO Before operating the stereo or CD player, read operation manual enclosed with stereo. Stereo PROGRAM AM/FM SCAN SOUND TUNE FG000108 Figure 131 Reference Reference Description Description Number Number Power / Volume Control Preset Station Sound Mode Selector Tape Ejection Band Selection Fast Forward / Rewind Tuning Up / Down...

  • Page 128: Miscellaneous Electrical Devices

    MISCELLANEOUS ELECTRICAL DEVICES Cabin Light A light is installed on the top of the operator's compartment. The light will work despite starter switch position. NOTE: If light is left "ON" for a long time while the engine is not running, the battery will be discharged. FG000417 Figure 133 Pilot Cutoff Switch...
  • Page 129 Otherwise, a fire could break out in the wiring harness and/or other components of the circuit. Always use original DOOSAN parts. Fuse Boxes There are two fuse boxes (Figure 137) on the left side of the heater box.

  • Page 130: Seat Adjustment

    SEAT ADJUSTMENT WARNING Adjust the seat position before starting operations or after changing the operator. Always fasten your seat belt while operating machine. Adjust the seat so that the control levers and pedals can be operated freely and easily with the operator back against the backrest.
  • Page 131 4. Reclining Position Adjustment Pulling up the right lever (4,Figure 138) allows the seat backrest to be moved forward or backward. Sit with your back against the seat back when adjusting it. If your back is not touching the seat back, the seat back may suddenly move forward.
  • Page 132 8. Seat Belt WARNING The seat belt is for the operator's safety and should always be worn. Before driving the machine, adjust the seat to the desired position for maximum comfort and machine control, then fasten the seat belt. Seat belts must be worn across the pelvic region and adjusted snugly to lessen the chance and severity of injury in case of an accident.
  • Page 133 9. Seat Back-pocket The seat has a seat back pocket. It is used for storing the operation and maintenance manual. 10. Left and Right Control Stand Adjustment For operator's convenience, the right and left control stands and seat can slide together, within a 160 mm (6.3 in) forward or backward travel distance.

  • Page 134: Ceiling Cover

    CEILING COVER NOTE: If the machine is equipped with the optional transparent ceiling cover never use any chemical cleaners on its surface. Only use warm water to wash dust and dirt from its surfaces, and after that, dry it with a soft fabric towel. FG000189 Figure 145 Opening the Ceiling Cover...

  • Page 135: Front Windows

    FRONT WINDOWS WARNING When leaving operator's seat, set the safety lever to "LOCK" position (Figure 147), if not a serious accident could occur by accidentally moving the work levers. FG000189 Figure 147 Front Upper Window The front upper window can be housed in the cabin's ceiling. Opening the Window WARNING When stowing front window in the cabin roof, make sure...
  • Page 136 Closing the Window WARNING Be careful that your hands are not caught in window frame. Lower bucket to ground. Set safety lever (Figure 147) on "LOCK", and shut down engine. FG000193 Figure 149 Holding upper handles (1, Figure 149) of front window with left and right-hand, pull lock levers (2, Figure 149) to release the lock.

  • Page 137: Door Side Latch

    DOOR SIDE LATCH The door side latch (1, Figure 152) is used to 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. FG000196 Figure 152 To release door from side of cabin, push the latch lever (2, Figure 153) down.

  • Page 138: Ashtray

    CABIN STORAGE COMPARTMENTS There are two storage compartments behind the operator's seat. The large compartment (1, Figure 154) is for storing nonperishable items. The covered other one (2, Figure 154) is interconnected with the air conditioner. So, it can be supplied with either warm or cool air when air conditioner is turned "ON".

  • Page 139: Sun Visor

    SUN VISOR The sun visor can be used to reduce the amount of sunlight coming through the front window and ceiling. When wanting to reduce the amount of sunlight coming in the front window, pull bar (1, Figure 157) down. When not wanting protection, hold the bar with left-hand and push the release button (2, Figure 157) with right-hand.

  • Page 140: Cup Holder

    CUP HOLDER There is a cup holder on the right side of the compartment (1, Figure 161). Open the access cover and lower it to a horizontal position. FG000205 Figure 161 DOOR WINDOW HOLDER When the machine is being operated with the cabin door window opened, window vibration can be reduced by tightening knob (1, Figure 162) against the window.

  • Page 141: Miscellaneous Access Covers And Doors

    MISCELLANEOUS ACCESS COVERS AND DOORS Side Door Open the side access door and slide prop rod (1, Figure 164) in slot (2) until it locks at the end of slot. FG016076 Figure 164 Battery Box Door Opening Open door until locking device (1, Figure 165) latches. Closing While holding door, press locking device to release lock and close door.
  • Page 142 Operating Controls OP001121 2-70...

  • Page 143: Operation

    Operation TO HANDLE A NEW EXCAVATOR All DOOSAN 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 144: 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 145 Operational Checks Before Starting Engine 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. FG000211 Figure 1 Set safety lever on "LOCK" (Figure 1). Fasten seat belt.
  • Page 146 Engine Start WARNING Start the engine after sounding horn and making sure that there are no people or obstacles in the area. Perform all steps in “Operational Checks Before Starting Engine” on page 3-3. Set engine speed control dial slightly above "LOW IDLE" (Figure 3).
  • Page 147 After warming unit, check all operating indicators to make sure that all engine systems (oil pressure, coolant, etc.) are in the normal operating range. If any problems are noticed, CHECK shut down engine. Normal indicators are: FG013731 Figure 6 INDICATOR INSTRUMENT PANEL LIGHT OR GAUGE READING Engine Coolant Temperature Gauge...
  • Page 148 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 all steps in "Operational Checks Before Starting Engine". Set engine speed control dial slightly above "LOW IDLE" HAOB34L (Figure 7).
  • Page 149 After engine has started, release key. Key will return to the "I" (ON) position (Figure 10). After the engine starts, check all operating indicators to make sure that all engine systems (oil pressure, coolant, etc.) are in the normal operating range. If any problems are noticed, shut down engine.
  • Page 150 Connecting the Booster Batteries Shut down engine of the machine on which booster batteries (3, Figure 12) are mounted. Connect one end of red cable (1, Figure 12) to the positive (+) terminal of the machine batteries (4), and the other end to the positive (+) terminal of the booster batteries.
  • Page 151 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°...
  • Page 152 Hydraulic System Warm-up – Cold Weather Run engine at "LOW IDLE" (no load) for five minutes (Figure 16). HAOB290L Figure 16 Run engine for approximately five minutes set at the middle of the speed range, without a load (Figure 17). HAOB410L Figure 17 Set safety lever (1, Figure 18) on "UNLOCK"...
  • Page 153 Set engine speed control dial to "HIGH IDLE" (Figure 20). 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 for clearance and fully raise the front attachment. Slowly swing clockwise 3 revolutions.
  • Page 154 Engine Shut Down NOTE: Allow engine to idle for three - five minutes before shutting down the engine. If not allowed to idle, heat surge may develop which will damage the engine. Allowing the engine to idle will dissipate heat. Park excavator on level and firm ground.

  • Page 155: Safety Lever

    Check and Confirmation After Stopping Engine Repair excavator, if there are any coolant or oil leaks. Inspect front attachment and under carriage for abnormal appearances. Correct any problems. Fill fuel tank. Get rid of any accumulated flammable materials such as leaves and paper etc.

  • Page 156: Travel

    TRAVEL WARNING Before operating the travel levers, make 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).
  • Page 157 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. NOTE: "X" is the sprocket end of the track. OPTION: Straight Travel Pedal (Figure 27, dotted line view) - To travel straight, push travel control pedal forward or backward without using travel control levers.
  • Page 158 General Travel Instructions Set engine speed control dial (Figure 31) on desired speed. HAOB550L Figure 31 Set safety lever on "UNLOCK" position, and folding the front, raise it 40 - 50 cm (16 - 20 in) above ground. See Figure 32. 40 ~ 50 cm FG015776 Figure 32...
  • Page 159 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. FG015846 If excavator starts to slip or becomes unstable, lower Figure 34...
  • Page 160 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 161: Operating Instructions

    OPERATING INSTRUCTIONS Engine Speed Control Engine speed can be manually adjusted using the engine speed control dial, Increase engine speed by rotating the control knob clockwise. Decrease engine speed by rotating the control knob counterclockwise. IMPORTANT The engine speed control system has been set at the HAOA690L factory and should not require adjustment as part of routine Figure 39...
  • Page 162 Economy Mode When the starter switch is turned "ON" the power mode is automatically defaulted to the standard setting. Select a proper economy mode using button (2, Figure 41) before starting work. When the economy mode button (2, Figure 41) is pressed, a signal sounds, changing the economy mode to either "ON"...
  • Page 163 Boost Mode Power boost switch is used to gain maximum digging force. The power boost is activated while 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"...
  • Page 164 Work Levers (Joysticks) (ISO Style) WARNING Check surrounding area before swinging. When operating a lever while in auto idle, do it carefully, because the engine speed will increase rapidly. NOTE: When starting work, move work levers (joysticks) slowly FG000381 and check movement of swing and front attachment. Figure 44 This equipment is manufactured using the lever configuration described in ISO standards.
  • Page 165 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. FG000381 Figure 48 NOTE: When starting work, move work levers (joysticks) <ISO PATTERN>...
  • Page 166 Work Levers (Joysticks) (BHL Style) Left-hand Work Lever (Joystick) (Figure 48 and Figure 50) Boom down Boom up Left swing Right swing NOTE: The swing brake is spring applied and hydraulically released. It is always engaged when the work lever (joystick) is in "NEUTRAL" or the engine is shut down.

  • Page 167: 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 and 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 168 Do not use machine travel or swing when the bucket is in the ground to provide additional breakout force. See Figure FG015784 Figure 56 Do not use machine weight to provide additional breakout force. See Figure 57. When working on soft or muddy ground, make sure that the machine is not sinking.
  • Page 169 11. Make sure that there is adequate clearance from overhead electrical supply lines. See Figure 60. FG015758 Figure 60 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 61.
  • Page 170 15. Do not operate travel lever quickly when traveling in high range. • Avoid sudden starts. • When traveling in one direction come to a complete stop before reversing directions. Do not rock excavator back and forth with levers. • Avoid sudden stops.
  • Page 171 Working in Water 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 damage. FG015790 Figure 65 When working in water, do not operate in water over center of...

  • Page 172: Parking Excavator

    PARKING EXCAVATOR 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. FG015855 Figure 67 Park excavator on firm, level ground. Lower bucket to ground as shown in Figure 68.

  • Page 173: 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 174: 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 175 Hydraulic Breaker Operation NOTE: Hydraulic pressure and flow settings may need to be 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 176 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 75. HAOB970L Figure 75 Do not any lifting or towing with a breaker.
  • Page 177 To activate breaker Set breaker selector switch to "II" (BREAKER) position. Press lower button on top of right-hand work lever (joystick) to activate hydraulic breaker. Release lower button on top of right-hand work lever (joystick) to deactivate hydraulic breaker. FG000117 Figure 79 RIGHT-HAND WORK LEVER (JOYSTICK) Relief Valve Adjustment...
  • Page 178 100% 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. 105 116 FILTER (First Replacement)

  • Page 179: Adjusting The Pump Flow

    ADJUSTING THE PUMP FLOW NOTE: For further information, see “Flow Control” on page 2-44. On the instrument panel, press the flow control button , the flow control screen (Figure 82) will be displayed. Use "UP" ( ) or "DOWN" ( ) buttons to adjust flow rate.
  • Page 180 Shear Pedal Valve (Optional) Activating Shear with Pedal Valve Select "SHEAR" with selector switch on right panel. Make sure that stopper (Figure 85) is in "SHEAR" position. NOTE: When stopper is in "SHEAR" position, pedal valve can be moved/rocked in both directions. Two-way operation is possible by rocking pedal back and forth between positions (1 and 2, Figure 83).
  • Page 181 Rotating Pedal Valve (Optional) Attachment Rotating by Using the Pedal Valve Pressing end (1, Figure 86) is used to turn clockwise. Pressing Figure used turn counterclockwise. NOTE: Before activating the pedal, be sure to check the function of the attachment. FG000405 Figure 86 Locking the Pedal...

  • Page 182: 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. To prevent injury, do not exceed the rated load capacity of the machine.
  • Page 183 Lifting Known Weight The load chart is the governing factor when lifting known weights. It is recommended that you feel your way into any lift as a precaution against tip-over. Whenever possible, lift and swing payloads between the front idler area. Pick and Carry The machine has the ability to pick and carry payloads without added labor.

  • Page 184: Operation Under Unusual Conditions

    OPERATION UNDER UNUSUAL CONDITIONS NOTE: “Maintenance Special Conditions” page 4-93 for other 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 185 Operation in Extreme Heat Continuous operation of the machine in high temperatures may cause machine overheat. Monitor engine transmission temperatures and stop machine for a cooling-off period whenever necessary. Make frequent inspections and services of the fan and radiator. Check coolant level in radiator. Check grills and radiator fins for accumulation of dust, sand and insects which could block the cooling passages.
  • Page 186 Operation in Dusty or Sandy Areas Operation of the machine can cause dust in almost any area. However, when in predominantly dusty or sandy areas, additional precautions must be taken. Keep cooling system fins and cooling areas clean. Blow out with compressed air, if possible, as often as necessary. WARNING Wear goggles when using compressed air.
  • Page 187 Operation at High Altitudes Normally, operation of machine at high altitudes will be as outlined in extreme cold. Before operating at high altitudes, engine fuel and air mixture may have to be adjusted according to appropriate engine manual. Check engine operating temperature for evidence of overheating.
  • Page 188 Operation OP001122 3-46...

  • Page 189: Preventive Maintenance

    OP001123 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. NOTE: The following pages list the service checks and their required intervals.
  • Page 190 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 Doosan Infracore Co., Ltd. 7-11, Hwasu-dong, Dong-gu, Incheon, Korea FG012987 Figure 4...
  • Page 191 Component Serial Numbers There are many serial numbers on each traceable components of the machine. For example, the engine serial number is stamped on the left side of the engine block, below the rocker cover. Additional engine information is described on a label (Figure 5) on the rocker cover.

  • Page 192: 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. NOTE: Certain types of maintenance may require the machine to be positioned differently. Always return machine to this position. Park on firm, level ground. Lower bucket to ground.
  • Page 193 Shut down engine by turning key to "O" (OFF) position. Remove key from starter switch. 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.

  • Page 194: Table Of Recommended Lubricants

    TABLE OF RECOMMENDED LUBRICANTS IMPORTANT It is highly recommend to use the Doosan Genuine Products, or products which meet the specification below. Using other products may damage the equipment. NOTE: Refer to the Maintenance Intervals Table for application points. Ambient Temperature...
  • Page 195 Engine oil must meet ACEA-E5 or API-CI-4. 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. Note that the mixing ratio is for reference purpose only, and is not an absolute standard.

  • Page 196: Fluid Capacities

    FLUID CAPACITIES Component Capacity 52 liters Oil Pan with Filter (13.7 U.S. gal.) Engine 69 liters Cooling System (18.2 U.S. gal.) 900 liters Fuel Tank (237.8 U.S. gal.) 350 liters Tank Level (92.5 U.S. gal.) Hydraulic Oil 790 liters System (208.7 U.S.
  • Page 197 Inspection, Maintenance and Adjustment OP001123...
  • Page 198 Description of Lubrication and Service Chart AUTO 250h 500h 1000h 2000h FG015856 Figure 11 Inspection, Maintenance and Adjustment OP001123 4-10...
  • Page 199 F100: Every 10 Hours For First 100 Hours. W10: Every 10 Hours If Operating In Water. EG: Ethylene Glycol - Doosan Genuine Antifreeze Solution (Drain and replace using this interval.) See “Engine Cooling System” on page 4-79, for further explanation.

  • Page 200: Maintenance Intervals

    MAINTENANCE INTERVALS SERVICE ITEM PAGE 10 Hour / Daily Service Grease Boom, Arm and Front Attachment Pins (for first 100 hours) 4-14 Check Engine Oil Level 4-14 Check Level of Hydraulic Oil Tank 4-15 Check for Leaks in Hydraulic System 4-16 Check Fuel Level 4-17...
  • Page 201 Major Parts - Periodic Replacement 4-58 12,000 Hour / Year Service Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) 4-59 ** These checks need to be completed by an authorized DOOSAN dealer. Inspection, Maintenance and Adjustment OP001123 4-13...

  • Page 202: Hour / Daily Service

    10 HOUR / DAILY SERVICE Grease Boom, Arm 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. Let anybody never be in the blowing direction. FG000500 Figure 12 Be careful to any kinds of works for nipples and hydraulic...

  • Page 203: Check Level Of Hydraulic Oil Tank

    Check Level of Hydraulic Oil Tank 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.

  • Page 204: Check For Leaks In Hydraulic System

    If oil level is above the "H" mark drain oil. Shut down engine and wait for the hydraulic oil to cool down. Drain the excess oil from drain plug (Figure 19) at the bottom of the tank into a suitable container, using a hose at the point (plug).

  • Page 205: Check Fuel Level

    Check Fuel Level WARNING Use extreme safety precautions while refueling to prevent explosions or fire. Immediately clean up any split fuel. At end of each work day, fill fuel tank. Add fuel through fuel fill tube (1, Figure 20). When working at a temperature of FG015798 0°C (32°F) or higher, use ASTM No.

  • Page 206: Check For Leaks In Fuel System

    Check for Leaks in Fuel System Perform an inspection of the engine compartment to verify that the fuel system is not leaking. If any is noted, determine the source of the leak and repair. Check Fuel Prefilter and Drain Water As Required NOTE: If water in fuel warning light (Figure 21) on instrument...

  • Page 207: Check Oil Level Of Swing Reduction Device

    Check Oil Level of Swing Reduction Device 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., loosen the plug slightly to allow pressurized air to escape.

  • Page 208: Clean Dust Net In Front Of Oil Cooler And Intercooler

    Clean Dust Net in Front of Oil Cooler and Intercooler 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. WARNING There should be no person in front of the fan in order to keep persons from being injured by scatterd material.

  • Page 209: Check Cooling System And Refill As Required

    Check Cooling System and Refill As Required WARNING Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to release any remaining pressure. Radiator cleaning is performed while the engine is running. Take extreme caution when working on or near a running engine.

  • Page 210: Inspect The Bucket Teeth And Side Cutters For Signs Of Wear

    Do not allow the replaceable bucket teeth to wear down to the point that the bucket adapter is exposed. See Figure NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers' buckets, refer to their specific instructions.

  • Page 211: Check Air Intake System

    Figure 33 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 found on air intake system.

  • Page 212: Check The Operation Of All Exterior Lights, Horn And Control Console Indicator And Monitor Lights

    Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights Turn engine starter switch to the "I" (ON) position and observe all of the indicator lights. Restore operation of any light bulbs that do not turn "ON" at this time.

  • Page 213: Hour / Weekly Service

    50 HOUR / WEEKLY SERVICE Perform All Daily Service Checks Grease Arm and Bucket Joint Pins Grease every 10 hours for first 100 hours and every 50 hours thereafter. NOTE: If the unit has been running or working in water the front attachment should be pressed on "Auto Greasing Manual Button"...

  • Page 214: Grease Swing Bearing (Only Manual Greasing)

    Arm link joint pin (1 point) Link joint pin (2 points) Arm bucket joint pin (1 point) Bucket link joint pin (1 point) Bucket cylinder rod pin (1 point) FG016128 Figure 36 FG016129 Figure 37 Grease Swing Bearing (Only Manual Greasing) Position the machine on firm, level ground.

  • Page 215: 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. NOTE: Dispose of drained fluid according to local regulations. NOTE: Always completely fill fuel tank at end of each workday to prevent condensation from forming on the inside walls of the tank.

  • Page 216: Hour / Monthly Service

    250 HOUR / MONTHLY SERVICE Perform All Daily and 50 Hour Service Checks Grease Boom and Arm Joint Pins Grease every 10 hours for first 100 hours and check the marked point of greasing every 250 hours thereafter. NOTE: If the unit has been running or working in water the front attachment should be pressed on "Auto Greasing Manual Button"...
  • Page 217 Boom cylinder head pin (2 points) FG016176 Figure 41 Boom foot pin (2 points) Boom cylinder rod pin (2 points) Arm cylinder head pin (1 point) FG016130 Figure 42 Boom arm joint pin (2 points) Arm cylinder rod pin (1 point) Bucket cylinder head pin (1 point) FG016131 Figure 43...

  • Page 218: Check Engine Fan Belt Tension

    Check Engine Fan Belt Tension IMPORTANT Alternator Water Idle Pulley Pump A loose fan belt can cause engine overheating, poor charging, and/or premature belt wear. A belt that is too tight can cause damage to the water pump, alternator bearing or belt.

  • Page 219: 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. FG016132 WARNING Figure 45 When checking, adjusting or replacing drive belts, care must be taken to prevent accidental cranking of the engine.

  • Page 220: 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., loosen the plug slightly to allow pressurized air to escape.

  • Page 221: Change Swing Reduction Device Oil (Drain And Refill After First 250 Hours)

    Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours) NOTE: Change swing reduction device oil after first 250 hours on a new machine and every 2,000 hours thereafter (See page 4-51). Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 250 Hours) NOTE:...

  • Page 222: Hour / 3 Month Service

    500 HOUR / 3 MONTH SERVICE Perform All Daily, 50 and 250 Hour Service Checks Grease Swing Gear and Pinion WARNING Greasing swing gear and pinion must be serviced by only one person. Remove inspection cover and inspect the condition of the grease.
  • Page 223 Change Engine Oil and Filter NOTE: Change engine oil and filter after first 50 hours of operation or rebuild, then every 500 thereafter. WARNING DO NOT change oil on a hot engine. Allow the engine to cool down before attempting to change the engine oil and filter to avoid burns by touching hot engine parts.
  • Page 224 Clean Air-Conditioning Outer Filter The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator's cabin. This filter should be cleaned out. NOTE: In the event that the unit is being operated in a dusty environment, the cleaning and replacement should be performed more frequently.
  • Page 225 Check and Clean Air-Conditioning Inner Filter WARNING All service and inspection of air-conditioning system should be performed with the starter switch in the "O" (OFF) position. WARNING FG000422 If using compressed air to clean the element, make sure Figure 56 that proper eye protection is worn.
  • Page 226 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core WARNING If compressed air, steam or water hit your body directly, there is danger of injury. Always wear protective glasses, mask and safety shoes during the cleaning precess. Make sure that all extra personnel are clear of the work area.
  • Page 227 Clean Outer Filter of Air Cleaner NOTE: Clean outer filter every 500 hours / 3 months of service. NOTE: If air cleaner clogged warning light (Figure 59) on instrument panel comes "ON" the air cleaner must be serviced. NOTE: When working in severely dusty conditions, the service interval should be shortened.
  • Page 228 Clean the outer filter (3, Figure 61) 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 62 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 229 Change of Fuel Prefilter Open the left rear side door to access fuel prefilter. Position a small container under prefilter. Drain fuel by opening drain valve on bottom of filter. NOTE: Dispose of drained fluids according to local regulations. FG 015800 Figure 64 Remove the bowl using supplied tool.
  • Page 230 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. FG016135 Figure 67 Unscrew fuel filter from head assembly. Discard fuel filter. NOTE: Dispose of drained fluids according to local regulations.

  • Page 231: Hour / 6 Month Service

    1,000 HOUR / 6 MONTH SERVICE Perform All Daily, 50, 250 and 500 Hour Service Checks Grease Swing Reduction Device Position the machine on firm, level ground. Lower the front attachment to the ground and shut down engine. Remove air vent plug (1, Figure 70) from swing reduction device.
  • Page 232 Replace Hydraulic Oil Return Filter, Drain Return Filter NOTE: Change hydraulic oil return filter after first 250 hours of operation or rebuild, and every 1,000 hours thereafter. NOTE: If return filter clogged warning light (Figure 72) on instrument panel comes "ON" the return filter must be serviced.
  • Page 233 Change Pilot Filter NOTE: Change pilot filter after first 250 hours of operation or rebuild, and every 1,000 hours thereafter. NOTE: If pilot filter clogged warning light (Figure 75) on instrument panel comes "ON" the pilot filter must be serviced. FG013895 Figure 75 WARNING...
  • Page 234 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., loosen the plug slightly to allow pressurized air to FG016109 escape.
  • Page 235 Change Air-Conditioning Outer Filter The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator's cabin. This filter should be cleaned out. NOTE: In the event that the unit is being operated in a dusty environment, the cleaning and replacement should be performed more frequently.
  • Page 236 Change Fuel Cap Filter WARNING External shock or damages to fuel cap may lead to permanent damage to filter. FG015720 Figure 83 See under the fuel cap as shown on (Figure 84). Rotate bolt to CCW direction to loosen. FG015684 Figure 84 After disengaging it as shown on (Figure 85), carefully lay it on floor.
  • Page 237 After disengaging as shown on (Figure 86), you may now exchange it to a new filter as shown on (Figure 87). FG015687 Figure 87 After exchanging to a new filter, you may now assemble back in reverse order. FG015688 Figure 88 Inspection, Maintenance and Adjustment OP001123 4-49...
  • Page 238 HFC-134a High No bubbles are seen. refrigerant. A flow of bubbles is visible. Check and Adjust Engine ** Contact your nearest DOOSAN dealer. Engine dealer for checking and adjusting the following items: • Engine Compression Pressure. • Injection Pressure.

  • Page 239: Hour / Yearly Service

    2,000 HOUR / YEARLY SERVICE Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks Change Swing Reduction Device Oil NOTE: Change swing reduction device oil after first 250 hours of operation or rebuild and every 2,000 hours thereafter. WARNING The gear oil is very hot after the machine has been operating.
  • Page 240 Replace Outer and Inner Air Cleaner Elements WARNING Never clean or attempt to remove the air cleaner element if the engine is running. NOTE: Replace outer element after cleaning 5 times or every 2,000 hours of service. NOTE: Replace inner element whenever a new outer element is installed.
  • Page 241 Mixed solution may degrade the capabilities of the system. It is recommended to use the standard product from Doosan. In the bitterly cold area or weather, the customer should frequently check the performance of the coolant for appropriateness for the weather, and then determine change cycle of the coolant.
  • Page 242 Install drain plugs (1, Figure 96), EGR plugs (3 and 4, Figure 98) and close drain valve (2, Figure 97) after coolant has completely drained from system. Reconnect heater hoses with clamps (5 and 6, Figure 99). Slowly fill cooling system with flushing solution to radiator neck.
  • Page 243 Make sure to clean any dirt or water from the top of the hydraulic tank, especially around the fill port and filter ports. 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. NOTE:...
  • Page 244 Drain hydraulic oil from tank into a container capable of holding 280 liters (74 U.S. gal.). After draining tank, install drain plug. IMPORTANT Be careful of squirting oil when removing drain plug. NOTE: Used filter and used oil should always be FG015797 disposed of according to local regulations.
  • Page 245 Check Alternator and Starter** **These checks need to be completed by an authorized DOOSAN dealer. Check All Rubber Antivibration Shock Mounts Perform and Record the Results of the Cycle Time Tests Inspect Machine to Check for Cracked or Broken Welds or other Structural...

  • Page 246: 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 247: Hour / 6 Year Service

    Standard ISO 8331 and EN982 CEN) European regulations state that the in-service life of any hydraulic hose exceed years. DOOSAN recommends the following; • Hoses at the customer premises cannot be stored more than 2 years before being discarded or installed on a machine.

  • Page 248: Air-Conditioning System

    Check the hose for cracking and damage. CAUTION When a leak occurs, dirt will accumulate in the area where the leak is. Consult a DOOSAN distributor or sales agency. Check Condenser Inspect the condenser for dust and debris. Clean if necessary.

  • Page 249: 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 250 BOLT BOLT TORQUE POINT TO BE INSPECTED DIA. QTY. HEAD kg•m ft lb SIZE Fixing bolt for front pin Fixing bolt for track frame and side frame 2824 2083 Fixing bolt for fan motor 16/12 24/19 24/11 265/108 195/80 Fixing bolt for fan pump Breaker Filter (Optional) PF1/2 Inspection, Maintenance and Adjustment...
  • Page 251 Joint bolt with engine mounting bracket and engine 1) Pump side • Tool: 19 mm ( • Torque: 10.5 kg•m (103 Nm, 123 ft lb) FG016173 Figure 105 2) Fan side • Tool: 22 mm ( • Torque: 17 kg•m (167 Nm, 123 ft lb) FG016083 Figure 106 Joint bolt and nut between engine mounting bracket and...

  • Page 252: Radiator Mounting Bolt

    Radiator mounting bolt • Tool: 24 mm ( • Torque: 27 kg•m (265 Nm, 195 ft lb) FG016086 Figure 109 Tightening bolt for hydraulic oil tank • Tool: 30 mm ( • Torque: 55 kg•m (539 Nm, 398 ft lb) FG016087 Figure 110 Tightening bolt for fuel tank...

  • Page 253: Tightening Bolt For Control Valve

    Tightening bolt for control valve • Tool: 30 mm ( • Torque: 55 kg•m (539 Nm, 398 ft lb) FG016090 Figure 113 Tightening bolt for swing reduction device • Tool: 36 mm ( • Torque: 95 kg•m (932 Nm, 687 ft lb) FG016091 Figure 114 Tightening bolt for swing motor...

  • Page 254: Joint Bolt With Cabin Mounting Rubber And Frame

    11. Joint bolt with cabin mounting rubber and frame • Tool: 17 mm ( • Torque: 6.5 kg•m (64 Nm, 47 ft lb) FG000454 Figure 117 Joint bolt with cabin mounting rubber and cabin • Tool: 24 mm ( • Torque: 21 kg•m (206 Nm, 152 ft lb) FG000455 Figure 118...

  • Page 255: Tightening Bolt For Travel Device

    13. Tightening bolt for travel device • Tool: 36 mm ( • Torque: 90 kg•m (883 Nm, 651 ft lb) FG016094 Figure 121 Tightening bolt for sprocket • Tool: 36 mm ( • Torque: 90 kg•m (883 Nm, 651 ft lb) FG016095 Figure 122 14.

  • Page 256: Tightening Bolt For Bottom Roller

    15. Tightening bolt for bottom roller • Tool: 36 mm ( • Torque: 90 kg•m (883 Nm, 651 ft lb) FG016098 Figure 125 16. Tightening bolt for track guard • Tool: 36 mm ( • Torque: 90 kg•m (883 Nm, 651 ft lb) FG016099 Figure 126 17.
  • Page 257 2) Arn cylinder, boom cylinder 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 Figure 129 FG016151 Figure 130 3) Bucket side...
  • Page 258 19. Fixing bolt for track frame and side frame • Tool: 55 mm ( • Torque: 288 kg•m (2,824 Nm, 2,083 ft lb) FG016107 Figure 133 20. Fixing bolt for fan motor • Tool: 24 mm ( ) (1) • Torque: 27 kg•m (265 Nm, 195 ft lb) •...
  • Page 259 21. Fixing bolt for fan pump • Tool: 12 mm ( • Torque: 17 kg•m (167 Nm, 123 ft lb) FG016153 Figure 135 22. Fixing breaker filter (Optional) • Tool: 10 mm ( • Torque: 27 kg•m (265 Nm, 195 ft lb) FG016175 Figure 136 Inspection, Maintenance and Adjustment...

  • Page 260: Bucket

    Shut the engine off and lock out the hydraulic controls before working on the bucket. NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers buckets, refer to their specific instructions. HAOC680L...
  • Page 261 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 bucket O-rings on a routine basis. If worn or FG000502 damaged, replacement is necessary. Figure 139 Roll old O-ring (1, Figure 140) onto boss (2) around bucket pin (3).

  • Page 262: Bucket Shimming Procedures

    BUCKET SHIMMING PROCEDURES New Bucket Installation If a new bucket is being installed on the excavator, measure the inside dimension between the bucket ears and the outside dimension across the arm mounting boss. Subtract the clearance on both sides from the difference of the two and shim accordingly, before assembly.

  • Page 263: Electrical System

    ELECTRICAL SYSTEM NOTE: Never disassemble electrical or electronic parts. Consult with a DOOSAN distributor or sales agency before servicing. Battery WARNING Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water.
  • Page 264 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 265 Fuses The fuses in the fuse box are used to protect the various electrical circuits and their components from being damaged. See Figure 146. The fuses used are standard automotive type fuses. The section on “Fuse Identification” on page 4-78, lists the circuits and the fuse amperage required for each circuit.
  • Page 266 Fuse Identification Fuse Box (1) Fuse Box (2) FG000542 Figure 148 Fuse Box One Fuse Box Two Name Capacity Name Capacity Warning Light (Optional) Horn 2-pump (Optional) Quick Clamp (Optional) Cigar Lighter Travel Alarm (Optional) 12V Power Auxiliary Mode Wiper, Washer Check Connector Lower Wiper (Optional) Pilot Cutoff...

  • Page 267: Engine Cooling System

    ENGINE COOLING SYSTEM General Keeping an engine's cooling system in peak operating condition, can have many benefits to keeping a machine in good operating condition. A properly functioning cooling system will; improve fuel efficiency, reduce engine wear, and extend component life. Always use distilled water in the radiator.
  • Page 268 Heavy duty diesel engines require a balanced mixture of water and antifreeze. Drain and replace the mixture every year or 2,000 hours of operation, which ever comes first. This will eliminate buildup of harmful chemicals. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant's freezing point and by raising its boiling point.
  • Page 269 If anticorrosive additive level is below 0.3, add 100% pure antifreeze to the radiator. If anticorrosive additive level is greater 0.8, add a 50% distilled water and antifreeze mixture to lower the additive reading. NOTE: In either case keep the antifreeze concentration level between 33% and 50%.
  • Page 270 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 271 Antifreeze Concentration Tables Ethylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons) (2,000 Hour / Yearly) Ambient Temperature Cooling Water Antifreeze -10°C (14°F) -15°C (5°F) -20°C (-4°F) -25°C (-13°F) -30°C (-22°F) -40°C (-40°F) Propylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons)

  • Page 272: Fuel Transfer Pump (Optional)

    FUEL TRANSFER PUMP (OPTIONAL) WARNING Do not dry operate fuel pump for more than fifteen seconds. • Cooling and lubrication of pump is achieved by fuel passing through pump. If pump is dry operated, heat generated by moving parts will cause damage to pump rotors, vanes and seals.
  • Page 273 The transfer pump is used to transfer fuel from a refueling source to the fuel tank. A check valve is installed in the inlet hose to prevent fuel from flowing back from fuel tank to source. A strainer is installed in inlet hose to prevent any foreign material from being introduced into transfer pump or fuel tank.

  • Page 274: 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 275: 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 all necessary precautions to make sure the machine won't move or shift position during service.
  • Page 276 The increased clearance recommended for muddy ground conditions is between 430 - 460 mm (16.93 - 18.11 in). The clearance should be approximately 460 mm (18.11 in) for operation over gravel, rocky terrain, or over sand or snow. WARNING The track adjusting mechanism is under very high-pressure.

  • Page 277: Venting And Priming Hydraulic System

    VENTING AND PRIMING HYDRAULIC SYSTEM Main System Pump NOTE: If pump is run without sufficient oil in the main hydraulic pump, damage can occur. Always vent pump of air after draining hydraulic system. Shut down engine. Remove flushing hose (1) from the adapter (2). Remove adapter (2) and O-ring from the pump housing.
  • Page 278 Swing Motor IMPORTANT If the air is not vented from the system, it will cause damage to the swing motor and bearings. NOTE: Perform this only when oil has been drained from swing motor. FG016142 Figure 156 Shut down engine. Disconnect drain hose and fill swing motor case with hydraulic oil.

  • Page 279: Long Term Storage

    LONG TERM STORAGE When a machine is taken out of service and stored for a time exceeding 30 days, steps must be taken to protect the machine. Leaving equipment outdoors exposed to the elements will shorten its life. An enclosure will protect the machine from rapid temperature changes and lessen the amount of condensation that forms in hydraulic components, engine, fuel tank, etc.
  • Page 280 During Storage • Once a month, start the engine and follow the "Hydraulic Oil Warm-up" procedures listed in this manual. NOTE: Remove all seals from the machine (i.e. crankcase and hydraulic breathers, engine air intake, fuel tank vent lines, etc.). Operate hydraulic functions for traveling, swing and digging two or three times for lubrication after "Hydraulic Oil Warm-up".

  • Page 281: Maintenance In Special Conditions

    MAINTENANCE IN SPECIAL CONDITIONS NOTE: See “Operation Under Unusual Conditions” on page 3-42 for other recommendations. Conditions Maintenance Required Operating in mud, water or rain. Perform a walk around inspection to check for any loose fittings, obvious damage to the machine or any fluid leakage. After completing operations, clean mud, rocks or debris from the machine.
  • Page 282 Inspection, Maintenance and Adjustment OP001123 4-94...

  • Page 283: Transportation

    OP001124 Transportation 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. DISASSEMBLY AND ASSEMBLY BEFORE AND AFTER TRANSPORTATION...
  • Page 284 Time Required Work Procedures Time Required Equipment to be Used Counterweight Disassembly 25 min Crane Disassembly and Track Side Frame Disassembly 45 min Crane Loading on Front Disassembly 1 h 20 min Crane Carrier Sub Total 2 h 30 min Front Assembly Crane Track Side Frame Assembly...
  • Page 285 Operation with side frame retracted could even result in a tip over, serious injury and death. Track Width Adjustment The DX700LC has a variable track width device that allows tracks to be retracted 300 mm on each side of machine. The retraction device should only be used during transportation.
  • Page 286 Turn superstructure so it is perpendicular to side frame to be retracted. Raise side frame to approximately a 15° angle from ground using a jack. Side frame should slide by its own weight and hit against stop. 90 ~ 110 NOTE: If side frame does not slide in this condition, allow side frame that is not contacting ground to...
  • Page 287 Turn superstructure so it is perpendicular to side frame to be extended. NOTE: Do not attach cable on side frame step. Attach one end of cable (1, Figure 161) (6 x 19 normal Z to ø14 – ø16 A type) on arm (2) and other end on side frame (3).

  • Page 288: Loading And Unloading

    Warning for Counterweight and Front Attachment Removal DANGER DOOSAN warns any user, that removal of counterweight from machine, front attachment or any other part, may affect stability of machine. This could cause unexpected movement, resulting in death or serious injuries. DOOSAN is not liable for any misuse.
  • Page 289 (43' 12") (77.58 US tons) 650 mm shoe 4.2 m 7.7 m (25' 3") 5,130 mm 3,650 mm 13,085 mm 70.1 metric tons DX700LC (13' 9") boom (16' 10") (11' 12") (42' 11") (77.25 US tons) 650 mm shoe 2.9 m 6.65 m (21' 10")
  • Page 290 Make sure that trailer is parked on firm, level ground. See Figure 164. Make sure that ramps that are being used are designed to handle weight of excavator. If required, add blocking under 90 ~ 110 ramp to provide additional support. The ramp angle should be less than or not exceeding a 15°...
  • Page 291 The unit does not require disassembly for normal over-the-road transportation. If boom and arm need to be removed, counterweight will place more weight on rear of machine. Make sure to back excavator onto trailer so counterweight end of excavator is positioned on ramp first. See Figure 168.

  • Page 292: Lifting With Sling

    13. Make sure to secure excavator onto trailer before transporting. Place blocking (1, Figure 172) in front of and behind each track. Use chains or cable tie-downs (2) as required by local transportation laws. 14. Refer to Dimensions for Transportation table and drawing for overall machine height and width measurements.

  • Page 293: 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 294: Engine

    Water or dirt in fuel system. Clean system and add new fuel. Air in fuel system. Purge air from system. Engine stop control failed. Contact your DOOSAN dealer. Engine stop relay failed. Replace relay. Blown fuse. Replace fuse. Engine starts, runs only at Engine oil viscosity incorrect.

  • Page 295: Hydraulic System

    Refill. unevenly or surges. Plugged air intake system. Clean system and replace filter. Injection pump out of adjustment. Contact your DOOSAN dealer. Plugged fuel filter. Replace fuel filter. Water or dirt in fuel system. Clean system and add new fuel.

  • Page 296: Swing System

    Add hydraulic oil as required. power. Suction filter clogged. Clean filter. Hydraulic pumps faulty. Contact your DOOSAN dealer. Main relief pressure too low. Contact your DOOSAN dealer. Hydraulic pumps excavating. Bleed air from hydraulic pumps. Only one or two actions Overload relief pressure too low.

  • Page 297: Travel System

    TRAVEL SYSTEM Problem Cause Remedy Travel motion does not Center joint leaking. Repair or replace as required. function. Parking brake will not release. Repair parking brake. Travel motor failed. Repair or replace as required. Remote control valve failed. Repair or replace as required. Wrong pilot line connection.
  • Page 298 Troubleshooting OP000030...
  • Page 299 OP001125 Specification 1. EU Specification SPECIFICATION COMPONENT METRIC ENGLISH Bucket CECE 2.9 m 3.79 yd capacity PCSA 3.3 m 4.32 yd Equipment weight 70.4 metric tons 77.5 U.S. tons Engine Model ISUZU AH-6WGIX Type Water cooled - 6 cylinders Rated output 345 kw @1,800 rpm 463 hp @1,800 rpm Maximum torque...
  • Page 300 Overall Dimensions FG015838 Figure 1 Boom Type (One Piece) 7.7 m (25' 3") 6.65 m (21' 10") 3.55 m 2.9 m 4.2 m 2.9 m 2.6 m Arm Type (11' 8") (9' 6") (13' 9") (9' 6") (8' 6") Bucket Type (SAE) 3.3 m 3.3 m 3.0 m...
  • Page 301 Specification OP001125...
  • Page 302 2. North America Specification SPECIFICATION COMPONENT METRIC ENGLISH Bucket CECE 2.9 m 3.79 yd capacity PCSA 3.3 m 4.32 yd Equipment weight 71.9 metric tons 79.2 tons Engine Model ISUZU AH-6WGIX Type Water cooled - 6 cylinders Rated output 345 kw @1,800 rpm 463 hp @1,800 rpm Maximum torque 202 kg•m @ 1,300 rpm...
  • Page 303 Overall Dimensions FG015838 Figure 2 Boom Type (One Piece) 7.7 m (25' 3") 6.65 m (21' 10") 3.55 m 2.9 m 4.2 m 2.9 m 2.6 m Arm Type (11' 8") (9' 6") (13' 9") (9' 6") (8' 6") Bucket Type (SAE) 3.3 m 3.3 m 3.0 m...
  • Page 304 Working Range Ground FG015858 Figure 3 Specification OP001125...
  • Page 305 Boom Type (One Piece) 7.7 m (25' 3") 6.65 m (21' 10") 3.55 m 2.9 m 4.2 m 2.9 m 2.6 m Arm Type (11' 8") (9' 6") (13' 9") (9' 6") (8' 6") Bucket Type (SAE) 3.3 m 3.3 m 3.0 m 3.9 m 4.5 m...
  • Page 306 APPROXIMATE WEIGHT OF WORKLOAD MATERIALS IMPORTANT Weights are approximations of estimated average volume and mass. Exposure to rain, snow or ground water; settling or compaction due to overhead weight and chemical or industrial processing or changes due to thermal or chemical transformations could all increase value of weights listed in table.
  • Page 307 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 308 Specification OP001125 7-10...
  • Page 309 1INDEX 4-71 Numerics Tooth 4-43 1,000 Hour / 6 Month Service 4-14 10 Hour / Daily Service 4-56 12,000 Hour / 6 Year Service 2-56 Cabin Light 4-49 2,000 Hour / Yearly Service 2-66 Cabin Storage Compartments 4-28 250 Hour / Monthly Service 2-12 Cabin Work Light Switch 4-55...
  • Page 310 4-74, 6-1 Electrical System Engine Gauges 4-54 Adjust Valve Clearance 2-22 Engine Coolant Temperature Gauge 4-48 Check and Adjust Engine 2-22 Fuel Gauge 2-25 Check Warning Light 2-24 Hour Meter 2-22 Coolant Temperature Gauge 2-23 Hydraulic Oil Temperature 2-25 Coolant Temperature Warning Light 2-23, 2-27 Multifunction Gauge 2-69...
  • Page 311 2-24 3-43 Engine Oil Pressure Warning Light Extreme Heat 2-26 3-45 Preheating Indicator Light High Altitudes 2-26 3-44 Work Light Rainy or Humid Conditions 3-44 Inspecting Engine Before Starting Salt Water Areas 4-23 Inspection, Maintenance and Adjustment Operation of All Switches 2-18, 2-20 2-46 Instrument Panel...
  • Page 312 4-21 2-55 Refill Cooling System Stereo 2-17 2-10 Rotating Buttons Audio Control Panel 3-39 4-54 Rotating Pedal Valve (Optional) Structural Damage 4-52 Suction Strainer 2-67 Sun Visor Swing Safety 4-26 Bearing 2-18, 3-13 Safety Lever 4-34 Gear and Pinion Safety Precautions 4-89 Motor 2-58...
  • Page 313 4-88 Table of Recommended Lubricants Venting and Priming Hydraulic System 3-31 4-89 Towing Procedure General Venting 4-27 4-88 Track Assemblies Hydraulic Cylinders 4-86 4-88 Track Tension Main System Pump 4-89 Tracks Swing Motor Extension and Retraction Extension and Retraction of Track Frames Frame Extension 2-12 Warning Light Switch...
  • Page 314 Index 950106-00012E...

Table of Contents