Doosan DX190W Operation And Maintenance Manual
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Doosan DX190W Operation And Maintenance Manual

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DX190W
Operation and Maintenance Manual
K1024512E
Serial Number 5001 and Up
September 2006
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.
K1024512E Operation and Maintenance Manual
Copyright Doosan 2006

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Александр
April 18, 2025

Проподает ход назат и вперёд

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1 comments:
Mr. Anderson
May 10, 2025

A possible cause for the Doosan DX190W to lose forward and backward movement is if the swing brake is engaged. The swing brake is spring-applied and hydraulically released, and it remains engaged when the joystick is in the "NEUTRAL" position or the engine is shut down. This could prevent movement if not properly released.

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Summary of Contents for Doosan DX190W

  • Page 1 Serial Number 5001 and Up September 2006 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 Excavator............1-1 Location of Safety Labels..............1-5 Summary of Safety Precautions for Lifting in Digging Mode.... 1-13 Unauthorized Modifications.............. 1-14 General Hazard Information............. 1-14 Before Starting Engine..............1-23 Machine Operation................1-27 Maintenance ..................
  • Page 4 Ceiling Cover ................... 2-67 Front Windows ................. 2-68 Door Side Latch ................2-70 Cabin Storage Compartments ............2-71 Ashtray..................... 2-71 Sun Visor ..................2-72 Hanger ..................... 2-72 Cup Holder..................2-73 Door Window Holder................ 2-73 Emergency Glass Breaking Tool ............. 2-73 Miscellaneous Access Covers and Doors........
  • Page 5 Lubrication and Service Chart............4-8 Maintenance Intervals..............4-12 10 Hour / Daily Service ..............4-15 50 Hour / Weekly Service ..............4-25 250 Hour Service ................4-29 500 Hour / 3 Month Service ............. 4-35 1,000 Hour / 6 Month Service ............4-46 2,000 Hour / Yearly Service .............
  • Page 6 Brakes....................6-7 Specification ................7-1 Specification..................7-1 Overall Dimensions................7-3 Working Range .................. 7-5 Index ...................8-1 Table of Contents K1024512E...

  • Page 7: Safety

    OP000527 Safety TO THE OPERATOR OF A 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 ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents. Always observe safety...
  • Page 10 Safety precautions are described in SAFETY from page 1-5 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. If any procedures or...

  • Page 11: Location Of Safety Labels

    LOCATION OF SAFETY LABELS FG008689 Figure 1 There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs. Make sure that all 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 (190-00742, 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 Leaving Operator's Seat (190-00693, 190-00094) Sudden and unwanted machine movement can cause serious injury or death.
  • Page 14 5. 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 15 7. 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 16 9. 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 10. Warning Tag - Used When Inspection and Maintenance (190-00695, 190-00098) WARNING...
  • Page 17 11. Warning for a Hot Surface (190-00648A) 190-00648 ARO1210L 12. Caution for Hood (190-00522) 190-00522 ARO1220L OP000527 Safety 1-11...
  • Page 18 13. Keep Out of the Swing Area (2190-3379, K1008571) 2190-3379 K1008571 FG000180 14. Warnings for Front Attachments (190-00652) 190-00652 ARO1230L Safety OP000527 1-12...

  • Page 19: 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 your individual operating environment, please consult your local DOOSAN representative. OP000527 Safety 1-13...

  • Page 20: 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 21 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 22 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a DOOSAN genuine part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.
  • Page 23 • Drive around obstacles and excessive rough terrain conditions. 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.
  • Page 24 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 25 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 26 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 27 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 28 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 29: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make the ground surface as hard and horizontal as possible before carrying out operations.
  • Page 30 areas. If the ground should collapse, the machine could fall or tip over and this could result in serious injury or death. Remember that the soil after heavy rain, blasting or after earthquakes, is weakened in these areas. Earth laid on the ground and the soil near ditches is loose. It can collapse under the weight of vibration of your machine and cause your machine to tip over.
  • Page 31 Engine Starting Walk around your machine before getting in the operator's cabin. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated.
  • Page 32 Before Operating Machine If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions.

  • Page 33: Machine Operation

    MACHINE OPERATION When Swinging or Changing Direction of Travel Before operating the machine or the work equipment, always observe the following precautions to prevent serious injury or death. • Start and operate the machine only while seated. • When changing the direction of travel from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing the HGB1014L-1...
  • Page 34 When traveling on rough ground, travel at low speed, and avoid sudden changes in direction. Always keep to the permissible water depth. Permissible water depth is to the center line of the axles. When traveling over bridges or structures on private land, check first that the bridge or structure can withstand the weight of the machine.
  • Page 35 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. FG006538 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 36 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 37 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 38 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 39: Maintenance

    DO NOT OPERATE lowered, nonactive position. when performing inspection or maintenance Warning tags, for controls are available from DOOSAN distributors. 190-00695 ARO1320L Figure 30 Clean Before Inspection or Maintenance Clean the machine before carrying out inspection and maintenance.
  • Page 40 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 41 fluids. Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes, clean the pipes or tubes thoroughly with a nonflammable solvent. Burn Prevention When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank.
  • Page 42 When carrying out welding repairs, carry out the welding in a properly equipped place. The welding should be performed by a qualified worker. During welding operations, there is the danger of, generation of gas, fire, or electric shock, so never let an unqualified worker do welding.
  • Page 43 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 44 Precautions When Working on Machine When carrying out maintenance operations on the machine, keep the area around your feet clean and tidy to prevent you from falling. Always do the following; • Do not spill oil or grease. • Do not leave tools laying about. •...
  • Page 45 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 46 – There is twisting or crushing at movable parts of hose. – Foreign material is embedded in the covering. – Hose end is deformed. NOTE: Refer “Hose In-service Lifetime Limit (European Standard ISO 8331 EN982 CEN)” on page 4-62, for additional European regulations.

  • Page 47: 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 48 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 49: 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. • Never go between the towing machine and the towed machine during the towing operation.

  • Page 50: 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 51: 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 52 maintain greater stability against side loads and wind gusts. 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.
  • Page 53 IMPORTANT Select the Digging Mode switch on the Instrument Panel before using the excavator for lifting work. Engine and hydraulic oil should both be fully warmed up to operating temperature before starting a lift. OP000527 Safety 1-47...
  • Page 54 Boom 17 1 Bucket UNIT (Free on wheel / Dozer and outrigger on ground) (Free on wheel / Dozer and outrigger on ground) FG008826 Figure 48 METRIC (5.2 m One-Piece Boom, 2.6 m Arm) A (m) Max. Reach Chassis Frame Attachment B (m) R-Rear Dozer Only Up...
  • Page 55 A (m) Max. Reach Chassis Frame Attachment B (m) R-Rear Dozer Only Up *5.74 *5.74 8.97 4.84 6.35 3.58 4.88 2.82 3.94 2.30 3.55 2.08 7.55 R-Rear Dozer Only Down *5.74 *5.74 8.77 6.60 6.20 4.79 4.77 3.72 3.85 3.02 3.47 2.73 7.55...
  • Page 56 FEET (17' 1" One-Piece Boom, 8' 6" Arm) A (ft) Max. Reach Chassis Frame Attachment B (ft) R-Rear Dozer Only Up *8.12 *8.12 17.04 R-Rear Dozer Only Down *8.12 *8.12 17.04 R-Outrigger Only Down *8.12 *8.12 17.04 F-Dozer + R-Outrigger *8.12 *8.12 17.04...
  • Page 57 Boom 17 1 Bucket UNIT FG008693 Figure 49 METRIC (5.2 m One-Piece Boom, 2.2 m Arm) A (m) Max. Reach Chassis Frame Attachment B (m) R-Rear Dozer Only Up R-Rear Dozer Only Down R-Outrigger Only Down F-Dozer + R-Outrigger Down R-Rear Dozer Only Up *6.00 4.14...
  • Page 58 A (m) Max. Reach Chassis Frame Attachment B (m) R-Rear Dozer Only Up *8.80 7.39 8.96 4.83 6.33 3.57 4.88 2.82 4.11 2.41 6.81 R-Rear Dozer Only Down *8.80 *8.80 8.76 6.59 6.18 4.77 4.76 3.72 4.02 3.16 6.81 R-Outrigger Only Down *8.80 *8.80 8.47...
  • Page 59 FEET (17' 1" One-Piece Boom, 7' 3" Arm) A (ft) Max. Reach Chassis Frame Attachment B (ft) R-Rear Dozer Only Up *11.75 10.27 15.10 R-Rear Dozer Only Down *11.75 *11.75 15.10 R-Outrigger Only Down *11.75 *11.75 15.10 F-Dozer + R-Outrigger *11.75 *11.75 15.10 R-Rear Dozer Only Up...
  • Page 60 Boom 17 1 10 2 Bucket UNIT (Free on wheel / Dozer and outrigger on ground) (Free on wheel / Dozer and outrigger on ground) FG008694 Figure 50 METRIC (5.2 m One-Piece Boom, 3.1 m Arm) A (m) Max. Reach Chassis Frame Attachment B (m)
  • Page 61 A (m) Max. Reach Chassis Frame Attachment B (m) R-Rear Dozer Only Up *6.94 *6.94 8.87 4.74 6.27 3.50 4.81 2.75 3.87 2.23 3.26 1.89 7.92 R-Rear Dozer Only Down *6.94 *6.94 8.67 6.50 6.13 4.71 4.70 3.65 3.78 2.95 3.18 2.50 7.92...
  • Page 62 FEET (17' 1" One-Piece Boom, 10' 2" Arm) A (ft) Max. Reach Chassis Frame Attachment B (ft) R-Rear Dozer Only Up *7.37 *7.37 18.77 R-Rear Dozer Only Down *7.37 *7.37 18.77 R-Outrigger Only Down *7.37 *7.37 18.77 F-Dozer + R-Outrigger *7.37 *7.37 18.77...
  • Page 63 Boom 5.36 17 7 Bucket UNIT (Free on wheel / Dozer and outrigger on ground) (Free on wheel / Dozer and outrigger on ground) FG008695 Figure 51 METRIC (5.36 m Two-Piece Boom, 2.6 m Arm) A (m) Max. Reach Chassis Frame Attachment B (m) R-Rear Dozer Only Up...
  • Page 64 A (m) Max. Reach Chassis Frame Attachment B (m) R-Rear Dozer Only Up 9.06 4.90 6.43 3.65 4.94 2.87 3.98 2.33 3.30 1.95 *2.75 1.93 8.05 R-Rear Dozer Only Down 8.86 6.68 6.28 4.86 4.83 3.78 3.88 3.06 3.23 2.55 *2.75 2.53 8.05...
  • Page 65 FEET (17' 7" One-Piece Boom, 8' 6" Arm) A (ft) Max. Reach Chassis Frame Attachment B (ft) R-Rear Dozer Only Up *9.16 *9.16 *6.75 *6.75 18.54 R-Rear Dozer Only Down *9.16 *9.16 *6.75 *6.75 18.54 R-Outrigger Only Down *9.16 *9.16 *6.75 *6.75 18.54...
  • Page 66 Boom 5.36 17 7 Bucket : Front clamshell cradle Attachment & rear dozer blade UNIT (Free on wheel / Dozer and outrigger on ground) (Free on wheel / Dozer and outrigger on ground) FG008696 Figure 52 METRIC (5.36 m Two-Piece Boom, 2.3 m Arm) A (m) Max.
  • Page 67 A (m) Max. Reach Chassis Frame Attachment B (m) R-Rear Dozer Only Up 8.96 4.82 6.34 3.57 4.88 2.81 3.94 2.30 *3.08 2.08 7.56 R-Rear Dozer Only Down 8.76 6.59 6.20 4.78 4.76 3.72 3.85 3.02 *3.08 2.74 7.56 R-Outrigger Only Down 8.48 10.47 5.99...
  • Page 68 FEET (17' 7" Two-Piece Boom, 7' 7" Arm) A (ft) Max. Reach Chassis Frame Attachment B (ft) R-Rear Dozer Only Up *10.26 *10.26 *7.27 *7.27 17.09 R-Rear Dozer Only Down *10.26 *10.26 *7.27 *7.27 17.09 R-Outrigger Only Down *10.26 *10.26 *7.27 *7.27 17.09...

  • Page 69: Operating Controls

    OP000528 Operating Controls The "Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-4 “Operator's Area” on page 2-6 “Operational Controls and Panels” on page 2-8 “Instrument Panel” on page 2-26 “Multifunction Gauge Graphic Information” page 2-32 “Mode Selector Buttons”...
  • Page 70 WARNING! Warning lights. When any one or more of the warning lights on the control console, comes "ON," immediately stop operation and shut down unit. Investigate and correct the problem before proceeding with operation. Operating Controls OP000528...
  • Page 71 Operating Controls OP000528...

  • Page 72: Component Locations

    COMPONENT LOCATIONS FG008697 Figure 1 Operating Controls OP000528...
  • Page 73 Reference Reference Description Description Number Number Counterweight Wheel Chocks Muffler Bucket Tooth Engine Cover Side Cutter Engine Bucket Hydraulic Oil Tank Ram Cylinders Fuel Tank Front Axle Control Valve Swing Lock Radiator And Oil Cooler Step Swing Motor Travel Motor Air Cleaner Propeller Shaft Swivel Joint...

  • Page 74: Operator's Area

    OPERATOR'S AREA FG006121 Figure 2 Operating Controls OP000528...
  • Page 75 Reference Reference Description Description Number Number Instrument Panel Stereo (See page 2-26) (See page 2-59) Ashtray Heater and Air Conditioner Unit (See page 2-71) Dozer Blade Work Lever Steering Handle Left-Control Stand (See page 2-18) (See page 2-8) Switch Panel Left-Stand Tilting Lever (See page 2-8) (See page 3-14)

  • Page 76: Operational Controls And Panels

    OPERATIONAL CONTROLS AND PANELS FG006122 Figure 3 Operating Controls OP000528...

  • Page 77: Instrument Panel

    Reference Reference Description Description Number Number Starter Switch Cigarette Lighter Engine Speed Control Dial Power Socket For 12V Quick Clamp Switch (Optional) Warning Light Switch (Optional) Auxiliary Mode Switch Overload Warning Switch (Optional) Emergency Stop Switch Fuel Heater Switch (Optional) Audio Control Panel Seat Warmer Switch (Optional) Ram Lock Switch...
  • Page 78 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 79 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 80 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 81 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 82 9. Work Light Switch Operates the work lights mounted on the boom. In this position, work light are turned "OFF". In this position, work light will turn "ON". CAUTION! Be certain that the work lights are turned "OFF" when FG002177 traveling on the streets.
  • Page 83 WARNING! Set the parking brake switch in the "I"(APPLIED) position before leaving the excavator. Make sure to "APPLY" the parking brake switch before trying to start the excavator. CAUTION! Do not use the parking brake to stop the excavator, except in an emergency; otherwise, it might cause premature wear or damage of the brake.
  • Page 84 14. Heater and Air Conditioner Control Panel This panel is used to control air conditioner and heater in operator's compartment. Refer to “Heater and Air OUTSIDE AUTO AUTO Conditioner Control Panel” on page 2-53 for more details. TEMP MODE FG000029 Figure 21 15.
  • Page 85 17. Warning Light Switch (Optional) If unit is equipped with a warning light, push this switch to activate it. In this position, the warning light is turned "OFF." In this position, the warning light turns "ON" and will start flashing. FG000027 Figure 24 18.
  • Page 86 20. Seat Warmer Switch (Optional) If the seat is equipped with the optional seat warmer, push this switch to activate it. When the seat is warmed, the warmer is automatically turned "OFF." In this position, the seat warmer is turned "OFF." In this position, the seat warmer is turned "ON."...
  • Page 87 23. Horn Button (Left-hand Work Lever) Press the lower button on the top of the left-hand work lever (joystick) to sound horn. NOTE: The starter switch must be "ON." FG006175 Figure 30 24. 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.
  • Page 88 26. Shear Buttons For a machine equipped with shear, press the two upper buttons on the top of the right-hand work lever (joystick) to open or close the shear. Left button is for closing (crowd), right button is for opening (Dump). NOTE: These buttons work with the breaker/boost/ shear selector switch.
  • Page 89 29. Photo Sensor The photo sensor detects the radiant energy of the sun. In auto mode the air conditioner will automatically adjust the air temperature based on to the detected radiant energy. FG000399 Figure 36 OP000528 Operating Controls 2-21...
  • Page 90 Steering Console FG002181 Figure 37 Reference Reference Description Description Number Number Combination Switch Ram Lock Indicator Light Transmission Selector Switch High Beam Indicator Light Work/travel Selector Switch Left Turn Signal Light & Hazard Warning Light Right Turn Signal Light & Hazard Warning Light Hazard Warning Light Switch Combination Switch (LH)
  • Page 91 NOTE: Do not operate windshield wiper without any washer fluid. If you operate it in spite of running out of fluid, the washer motor may be damaged. Check level in washer tank, and add fluid as required. NOTE: If you use soapy water or synthetic detergent instead of window cleaning fluid, the wiper blade or painted surfaces may be damaged.
  • Page 92 control dial. If the brakes are applied or if the travel selector lever is moved to the "NEUTRAL" position the cruise control is turned "OFF." When the auto idle mode is selected, the engine speed is lowered approximately 4 seconds after the cruise is turned "OFF."...
  • Page 93 Ram Lock Indicator Light This light turns "ON" when the ram lock cylinder is "APPLIED". FG002187 Figure 44 High Beam Indicator Light This light turns "ON" when the head lights are turned to "HIGH BEAM." HA0O2023 Figure 45 Right Turn Signal Light & Hazard Warning Light This light blinks when right turn signal is turned "ON."...
  • Page 94 INSTRUMENT PANEL CHECK 1700 E/G SPEED POWER AUTO FG006164 Figure 48 Reference Reference Description Description Number Number Fuel Gauge Parking Brake Indicator Light Engine Coolant Temperature Power Mode Selector Button Gauge (See page 2-38) Hydraulic Oil Temperature Trenching Mode Selector Button Gauge (See page 2-38) Multifunction Gauge and Graphic...

  • Page 95: Figure 49

    Functional check When the engine starter switch is turned to the "I" (ON) position, all gauge bands, switch/button indicator lights and indicator/ warning lights will turn "ON" and the alarm buzzer will sound about two seconds. During this functional check, a LOGO will appear on the multi function gauge in the graphic information area (3 and 4, Figure 48).

  • Page 96: Engine Coolant Temperature

    2. Engine Coolant Temperature Gauge The colored bands indicate the temperature of the engine coolant. 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 97: Multifunction Gauge And Graphic

    4. Multifunction Gauge and Graphic Information Area 02/05 [MO] 11:30 See “Multifunction Gauge and Graphic Information” on page 2-32. This section will have a more in-depth explanation of the display area. E/G SPEED FG000043 Figure 52 5. Digital Clock A digital clock, shows the current time. The displayed contents are as follows.

  • Page 98: Charge Warning Light

    7. Charge Warning Light This indicator light will turn "ON" when the engine starter switch is turned "ON," and should go "OFF" after the engine starts. If it does not turn "OFF," shut the engine down immediately and determine the cause of the problem.

  • Page 99: Engine Check Warning Light

    engine to idle will dissipate heat. Check the coolant level, look for a loose fan belt, inspect for debris around radiator, and so on. When the temperature reaches the normal range, the engine speed will automatically recover. 10. Engine Check Warning Light This indicator light will turn "ON,"...

  • Page 100: 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 02/05 [MO] 11:30 seconds. When the LOGO disappears, the multifunction gauge and graphic information screen will appear.
  • Page 101 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 102 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 66 Rear Hydraulic Pump Pressure The rear pump pressure is numerically displayed.
  • Page 103 Examples of Warning Display 02/05 [MO] 11:30 02/05 11:30 1700 1700 E/G SPEED E/G SPEED E/G SPEED FG000059 FG006167 FG000060 <2 kinds of warning displayed> <4 kinds of warning displayed> <6 kinds of warning displayed> Figure 69 Hydraulic Oil Overheat Warning If the hydraulic oil temperature is too high, this symbol appears on the screen.
  • Page 104 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 72 Return Filter Clogged Warning This symbol indicates when the hydraulic return filter is clogged.
  • Page 105 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 106: Mode Selector Buttons

    MODE SELECTOR BUTTONS Power Mode Selector Button POWER Trenching Mode Selector Button AUTO Auto Idle Selector Button Flow Control Button FG001338 Figure 78 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 107: Auto Idle Selector Button

    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 108: Setting Main Menu

    SETTING MAIN MENU By using a combination of the selector buttons (Figure 84), you can review and set the contents of the display screen. Items 02/05 [MO] 11:30 such as language, time and filter/oil information can be checked, and if necessary, set with new information. E/G SPEED FG000043 Figure 83...

  • Page 109: Down Arrow Button

    2. Down Arrow Button Down arrow button ( ), is used to move a menu item "Down" or to the "Right." FG000069 Figure 86 3. Display Selector Button (ESC - Escape) Display selector button ( ), is used to change the displayed information on the screen.
  • Page 110 Display Selection and Escaping Display Selection When the display button (Figure 89) is pressed for more than three seconds, the main menu screen (Figure 91) 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 111 Language M A I N M E N U When the cursor is on "Language," press the "SELECT" ( 1. Language button. The language submenu will appear. 2. Set Clock The desired language can be selected by using the "UP" ( ) or 3.
  • Page 112 '00' Minute Setting S E T CLO CK Simultaneously press the "SELECT" ( ) button and "UP" ) button. 0 6 : 0 5 If the displayed time is 30 minutes or less, the clock will display the preceding hour. 2 0 0 4 0 6 / 2 9 If the displayed time is more than 30 minutes, the clock will display the succeeding hour.
  • Page 113 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 98 Filter / Oils Operating Hour Reset FILTER / OIL INFO After changing a filter or oil, reset the operating hour to zero (Hrs: 0000).
  • Page 114 Adjust Display M A I N M E N U 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.
  • Page 115 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 116 Select adoption (lock) or nonadoption (unlock) at set : UP : DOWN : SELECT password menu. FG000229 NOTE: Keep in mind never to forget password. Figure 105 NOTE: Please contact a DOOSAN distributor, if you forget your password. Operating Controls OP000528 2-48...

  • Page 117: Flow Control

    FLOW CONTROL 02/05 [MO] 11:30 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. E/G SPEED FG000043 Figure 106...
  • Page 118 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 119: Operation Selection Display

    OPERATION SELECTION DISPLAY In the monitor you can see the application that is currently selected. Power Boost Selection 02/05 [MO] 11:30 E/G SPEED FG000257 Figure 112 Breaker Selection 02/05 [MO] 11:30 E/G SPEED FG000258 Figure 113 Shear Selection 02/05 [MO] 11:30 E/G SPEED FG000259 Figure 114...
  • Page 120 Overload Alarm Selection (Optional) 02/05 [MO] 11:30 E/G SPEED FG000260 Figure 115 Quick Clamp Operation Selection (Optional) 02/05 [MO] 11:30 E/G SPEED FG000388 Figure 116 Operating Controls OP000528 2-52...

  • Page 121: Heater And Air Conditioner Control Panel

    HEATER AND AIR CONDITIONER CONTROL PANEL Location of Controls and Vents FG007166 Figure 117 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 118 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 120 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 Used to direct air flow to upper portion of operator's cabin from both the front and rear. FG002198 Figure 124 Used to direct air flow to upper portion of operator's cabin from both the front and rear. It will also deliver air to the lower portion of operator's cabin from under the operator's seat.
  • Page 125 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. The select mode is displayed on the LCD. FG000101 Figure 128 "A"...
  • Page 126 Defroster Button Used to direct air flow to front window. FG000106 Figure 132 10. LCD Display This display shows the current setting. OUTSIDE Memory Function AUTO The air conditioner panel has a memory function. When the starter switch is turned "OFF" the settings for the panel, will be stored.

  • 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 134 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 CD Player (Optional) AST/DIR FG000109 Figure 135 Operating Controls OP000528 2-60...

  • Page 129: 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 136 Pilot Cutoff Switch...
  • Page 130 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 140) on the left side of the heater box.

  • Page 131: 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 132 4. Reclining Position Adjustment Pulling up the right lever (4,Figure 141) 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 133 Seat Belt Locking and Unlocking Insert belt end (1, Figure 143) into the buckle (2). Pull the belt to check that belt end is locked into buckle. Adjust belt length so that it comfortably tight against the operator's pelvic region (hipbone). HAOB140L Figure 143 Press the button (3, Figure 144) in the center of buckle (2)
  • Page 134 12. Air Suspension Seat (Optional) The operator seat is also available with air suspension for even better comfort. The switch (12, Figure 146) in the middle of the seat can be used to adjust the air cushion. If the switch is pressed, the seat become harder, and pulling it out makes the seat softer, when the air is bleed out.

  • Page 135: 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. Opening the Ceiling Cover Lower bucket to ground.

  • Page 136: Front Windows

    FRONT WINDOWS WARNING! When leaving operator's seat, set the safety lever to "LOCK" position (Figure 150), if not a serious accident could occur by accidentally moving the work levers. Front Upper Window The front upper window can be housed in the cabin's ceiling. FG002254 Figure 150 Opening the Window...
  • Page 137 Closing the Window WARNING! Be careful that your hands are not caught in window frame. Lower bucket to ground. Set safety lever (Figure 150) on "LOCK," and shut down engine. FG000193 Figure 152 Holding upper handles (1, Figure 152) of front window with left and right-hand, pull lock levers (2, Figure 152) to release the lock.

  • Page 138: Door Side Latch

    DOOR SIDE LATCH The door side latch (1, Figure 155) 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 155 To release door from side of cabin, push the latch lever (2, Figure 156) down.

  • Page 139: Cabin Storage Compartments

    CABIN STORAGE COMPARTMENTS There are two storage compartments behind the operator's seat. The large compartment (1, Figure 157) is for storing nonperishable items. The covered other one (2, Figure 157) is interconnected with the air conditioner. So, it can be supplied with either warm or cool air when air conditioner is turned "ON."...

  • Page 140: 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 160) down. When not wanting protection, hold the bar with left-hand and push the release button (2, Figure 160) with right-hand.

  • Page 141: Cup Holder

    CUP HOLDER There is a cup holder on the right side of the compartment (1, Figure 164). Open the access cover and lower it to a horizontal position. FG000205 Figure 164 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 165) against the window.

  • Page 142: Miscellaneous Access Covers And Doors

    MISCELLANEOUS ACCESS COVERS AND DOORS Side Door Open the side access door and slide prop rod (1, Figure 167) in slot (2) until it locks at the end of slot. FG008145 Figure 167 Battery Box Door Opening Open door until locking device (1, Figure 168) latches. Closing While holding door, press locking device to release lock and close door.
  • Page 143 Dozer Cylinder Protection Cover Unlock chain (Figure 170) connection between dozer cylinder protection cover and chassis frame out of this chassis frame. Completely open the dozer cylinder protection cover. CAUTION! In order to avoid malfunction when opening dozer cylinder protection cover, you must work it after fixing the facilities on a planar ground surface and then putting down the dozer FG008148 Figure 170...

  • Page 144: Swing Lock Pin And Mechanism

    SWING LOCK PIN AND MECHANISM This wheel excavator is equipped with a swing lock device, which should be used when transporting or traveling on streets. The device consists of a pin and two holes which must be aligned and through which the pin is placed. This serves to keep the swing device from accidentally moving and causing damage to other vehicles or people in its path.

  • Page 145: 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 146: 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 transmission and axle gear oil after first 500 hours of operation.
  • Page 147 Operational Checks Before Starting Engine WARNING! When leaving operator's seat, set the safety lever and stand on "LOCK" (Figure 1) position, if not a serious accident could occur by accidentally moving the travel or work levers. FG006173 Set safety lever and stand on "LOCK" (Figure 1). Figure 1 Fasten seat belt.
  • Page 148 NOTE: If all of the indicator lights do not come "ON" when the key is first turned, there is a problem. A warning buzzer will sound for about 2 seconds. The sound of the engine control motor may be heard while it rotates to the correct starting position.
  • Page 149 " " Turn starter switch to (START) position (Figure 7). Engine should start in approximately 5 seconds. WARNING! If the engine does not start after approximately 15 seconds of cranking, release the starter switch. Wait about 5 minutes and repeat above step. FG000085 Figure 7 After engine has started, release key.
  • Page 150 Check color of exhaust smoke. • No color or light blue - Engine is running in good condition. • Black - Incomplete combustion. Check cause. • White or dark blue - Engine is burning engine oil. Check cause. 10. Check for usual engine vibration and noises. If any are heard or felt, investigate cause.
  • Page 151 Turn starter switch to the "I" (ON) position (Figure 11). When preheat cycle is completed, the preheat indicator light (1, Figure 12) will turn "OFF". FG000084 Figure 11 CHECK FG007105 Figure 12 After the preheat completion, immediately turn starter " "...
  • Page 152 Starting Engine With a Booster Cable WARNING! An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Charge batteries in a well ventilated area. HAOA440L Always wear eye protection when starting a machine Figure 14 with jumper cables.
  • Page 153 the machine batteries as possible. DO NOT CONNECT DIRECTLY TO THE NEGATIVE BATTERY TERMINAL. Start the engine. Disconnecting the Booster Batteries Disconnect black negative (-) cable (2, Figure 15) from the machine frame (5) first. Disconnect the other end of black negative (-) cable (2, Figure 15) from the booster batteries (3).
  • Page 154 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 155 Hydraulic System Warm-up – Cold Weather Run engine at "LOW IDLE" (no load) for five minutes (Figure 19). HAOB290L Figure 19 Run engine for approximately five minutes set at the middle of the speed range, without a load (Figure 20). HAOB410L Figure 20 Set safety lever (Figure 21) and stand on "UNLOCK"...
  • Page 156 Set engine speed control dial to "HIGH IDLE" (Figure 23). 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 157 Shut down engine by turning key to "O" (OFF) position (Figure 27). Remove key from starter switch. Check and Confirmation After Stopping Engine Repair excavator, if there are any coolant or oil leaks. Inspect front attachment and chassis frame for abnormal FG000175 appearances.

  • Page 158: Safety Lever

    SAFETY LEVER WARNING! When stopping engine or leaving the operator's seat, "LOCK" the safety lever, otherwise, a serious accident may occur by accidental movement of travel and work levers. Whenever leaving the operator's seat, make sure the engine is shut down and the safety lever is "LOCKED." Especially, when adjusting the seat, control stands, or raising the front window, lower window, or ceiling cover, never forget to lock the safety lever in its "LOCKED"...

  • Page 159: Travel

    TRAVEL WARNING! Make sure to read and understand all operating controls, Cautions, and Warnings before traveling. Obey all traffic rules and regulations. Do not travel faster than conditions allow. Make sure to follow all local and state rules and regulations regarding over road...
  • Page 160 Before Traveling Check all tires to make sure that they are properly inflated and are not damaged. Make sure that all excess mud, stone, etc. has been removed from the tires. Fully raise and secure all outriggers and the dozer blade, be sure to lock the outrigger legs(Figure 30).
  • Page 161 Over the Road Traveling Procedures Make sure that the "Brake Oil Pressure" warning light is "OFF". After making sure that the front attachment is facing forward, release the parking brake. Using the right-hand control arm, select either forward or reverse travel direction and step on the accelerator pedal. NOTE: The accelerator pedal functions in two ways.
  • Page 162 NOTE: As the brake pedal is applied, and if it is pressed all the way to the floor, a mechanical lock will engage and hold the pedal in the fully applied position (1, Figure 32). Step on the release lever and the brake pedal will return to the upright position.
  • Page 163 Never travel up or down a slope with a vertical angle greater than 20°, or sideways on a slope with a vertical angle of greater than 5°. Traveling On A Slope If the engine stops when traveling on a slope, lower the bucket to the ground, make sure all controls are in the "NEUTRAL"...
  • Page 164 Parking Slowly release the pressure on the accelerator pedal. FG002656 Figure 35 Step on the brake to fully stop the machine. FG002657 Figure 36 Be certain to set the work levers (joysticks) and transmission select lever to "NEUTRAL". FG002185-2 Figure 37 If you are using the manual speed control dial, reduce the engine speed to "LOW IDLE".
  • Page 165 Lower bucket, dozer blade and outrigger to ground. FG006562 Figure 39 Set parking brake switch to the "I" position. This will ensure that the parking brake is "APPLIED". FG002178-1 Figure 40 Shut down engine by turning key to "O" (OFF) position (Figure 41).
  • Page 166 Travel Problems If a problem develops during the travel mode, move the machine to the side of the road as safely as possible. Determine the cause of the problem and correct it if possible. If a hydraulic leak develops, lower the bucket and the dozer blade to the ground, shut down the engine, and release the air pressure from the hydraulic tank.

  • Page 167: Operating Instructions

    IMPORTANT If the engine rpm is being manually adjusted, the equipment will not function in its optimum capacity. Please contact a DOOSAN distributor or service center for repairs. FG002663 Figure 46 Engine speed can be controlled by either the manual accelerator pedal or the manual speed control dial.
  • Page 168 engine speed range control is available through either the accelerator pedal or the manual engine speed control dial (A – B, Figure 46). With the travel/work mode selector switch in the "WORK MODE" position, all hydraulic components are activated. Steering Wheel The steering wheel allows the precise steering of the excavator.
  • Page 169 Mode Selection More efficient work can be done by choosing a proper power and work mode combination, suitable to type of work and conditions. Use the mode selection according to following guide. Power Mode When the starter switch is turned "ON" the power mode is automatically defaulted to the standard setting.
  • Page 170 Mode Selection Point Feature of Control • Trenching. TRENCHING The swing is faster and stronger • Excavating of side wall. MODE than boom or arm. • Required to constant swinging. Auto Idle Mode The system will automatically reduce engine speed to idle speed approximately four seconds after all of the control levers are in the neutral position.
  • Page 171 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 joysticks slowly and check movement of swing and front attachment and dozer (outrigger).
  • Page 172 Dozer Blade and Outrigger Control Lever (Figure 54 and Figure 56) Blade/Outrigger down 10. Blade/Outrigger up The dozer blade control lever is on the left control stand. To lower blade, push lever forward; to raise blade, pull lever backwards. Whenever dozer blade is being used to level ground, make sure to set travel speed control to "LOW SPEED"...
  • Page 173 Independent Outriggers (Option) If the machine is equipped with the optional independent outriggers. Independent outriggers are operated with dozer control lever and select switches. Select the outriggers with one or more of the switches, and then, push the lever forward to lower the outriggers, pull the lever backwards to raise the outriggers.

  • Page 174: 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 175 Do not continually "bottom out" the hydraulic cylinders. Machine damage may occur if the cylinders are fully extended or retracted, example: arm cylinder fully retracted and the bucket cylinder is extended to rotate the bucket into the ground. FG006568 Figure 64 Do not use machine travel or swing when the bucket is in the ground to provide additional breakout force.
  • Page 176 11. Do not excavate underneath the machine. See Figure 68. FG006572 Figure 68 12. Make sure that there is adequate clearance from overhead electrical supply lines. See Figure 69. FG006573 Figure 69 13. 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.
  • Page 177 15. Do not dig with the excavator tires raised. This can result in structural and mechanical failures. 16. 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.
  • Page 178 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. FG006578 Figure 74 When working in water, do not operate in water over center...

  • Page 179: Parking Excavator

    PARKING EXCAVATOR WARNING! Park excavator on firm, level ground. Avoid parking on slopes. If excavator must be parked on a slope, block wheels (1) using the supplied wheel chocks (See “Wheel Chocks” on page 2-76.) and place bucket teeth in ground. (Figure 76) FG006580 Figure 76...

  • Page 180: Towing Procedure

    TOWING PROCEDURE WARNING! Make sure that the towing vehicle can handle the weight of the unit being towed and that it has adequate braking capacity. Never use a damaged wire rope or chain. They could brake and cause a serious accident. Always wear gloves when handling a chain or wire rope.
  • Page 181 How to release the parking brake (manual mode) Set chock under tire so that vehicle would not move. Grease at grease nipple (A) of transmission at rear side of facilities by means of grease gun. Whence grease amount shall be about 30 cc. If grease leaks through relief valve (B), the parking brake release has been finished.

  • Page 182: 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 183 Do not use the breaker as a hammer. (Figure 82.) Do not drop breaker from extreme heights. The breaker is relatively heavy and drops fast. Do not drop breaker from extreme heights or damage to upper structure may result FG006582 Figure 82 Do not operate the breaker with the boom or arm cylinders fully extended (bottomed out).
  • Page 184 Do not do any lifting or towing with a breaker. (Figure 86.) FG006585 Figure 86 Operate the breaker only to the front and rear of the excavator. Do not use the breaker to either side of the excavator. Do not swing the breaker from side to side when operating it.
  • Page 185 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 89 RIGHT-HAND WORK LEVER (JOYSTICK) Relief Valve Adjustment...
  • Page 186 100% 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 187: Adjusting The Pump Flow

    ADJUSTING THE PUMP FLOW NOTE: For further information, see “Flow Control” on page 2-49. On the instrument panel, press the flow control button , the flow control screen (Figure 92) will be displayed. Use "UP" ( ) or "DOWN" ( ) buttons to adjust flow rate.
  • Page 188 Shear Pedal Valve (Optional) Activating Shear with Pedal Valve Select shear with the selector switch of the right panel. Two-way operation is possible by pressing the pedal back and forth between positions (1 and 2, Figure 93). When the pedal is in its center (at rest) position the valve is in "NEUTRAL"...
  • Page 189 Rotating Pedal Valve (Optional) Attachment Rotating by Using the Pedal Valve Pressing end (1, Figure 96) is used to turn front attachment (LH line high pressure). Pressing end (2, Figure 96) is used to turn front attachment (RH line high pressure). NOTE: Before activating the pedal, be sure to check the function of the attachment.

  • Page 190: 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 191 DANGER! If a load is picked up from the front zone and swung into the side zone, a tip-over could result causing a deadly or fatal injury. Lifting Known Weight The load chart is the governing factor when lifting known weights.

  • Page 192: Operation Under Unusual Conditions

    OPERATION UNDER UNUSUAL CONDITIONS NOTE: “Maintenance Special Conditions” page 4-94 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 193 If cold weather starting aid must be used, see "Engine Starting" COLD WEATHER START portion of this manual. 10. Clean off all mud, snow and ice to prevent freezing. Cover machine with tarpaulin if possible, keep ends of tarpaulin from freezing to ground. Operation in Extreme Heat Continuous operation of the machine in high temperatures may cause...
  • Page 194 Cover inactive machine with tarpaulin if no suitable shelter is available. Protect engine compartment, transmission and hydraulics from entrance of dust. In hot, damp, climates corrosive action will occur on all parts of the machine and will be accelerated during the rainy season. Rust and paint blisters will appear on metal surfaces and fungus growth on other surfaces.
  • Page 195 Operation in Salt Water Areas The corrosive effect of salt water and salt water spray is very extensive. When operating in salt water areas, observe the following precautions. When exposed to salt water, dry machine thoroughly and rinse with fresh water as soon as possible. Keep all exposed surfaces coated with preservative lubricating oil.

  • Page 197: Inspection, Maintenance And Adjustment

    OP000530 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 198 Product Identification Number (P. I. N.) Location A P.I.N. number, is stamped on the upper frame, under the boom foot (Figure 3). It is also stamped on the product identification plate (Figure 4) on the front side of the battery frame on the outside.
  • Page 199 Safety Precautions Make sure to lock out the hydraulic controls and post a notice (Warning Tag) that the machine is being serviced to prevent any unauthorized operation. Make sure to clean up any fluid spills, especially around the engine. Inspect all fuel lines to make sure that fittings, lines, filters and O-rings, etc., are tight and are not showing signs of wear or damage.

  • Page 200: 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 201 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 202: Table Of Recommended Lubricants

    TABLE OF RECOMMENDED LUBRICANTS NOTE: Refer to the Maintenance Intervals Table for application points. Ambient Temperature Kind of Reservoir Fluid °F 50 °C SAE 10W-30 Engine Oil * SAE 10W-40 Engine Oil SAE 15W-40 SAE 90 and API GL5 Swing Drive Gear Oil * SAE 80W-90 and API GL5 Case...
  • Page 203 Installed at factory. 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. **** Approved for the powershift transmission is oils according to the ZF list of lubricants TE-ML 07 and oils according to the ZF list of lubricants TE-ML 05 are permitted for axles.

  • Page 204: Fluid Capacities

    FLUID CAPACITIES Component Capacity 25 liters Oil Pan with Filter (6.6 U.S. gal.) Engine 24 liters Cooling System (6.3 U.S. gal.) 310 liters Fuel Tank (81.9 U.S. gal.) 116 liters Tank Level (30.6 U.S. gal.) Hydraulic Oil 205 liters System (54.2 U.S.
  • Page 205 Description of Lubrication and Service Chart 12, 17 250h 500h 1000h 2000h 22, 23 FG008698 Figure 11 OP000530 Inspection, Maintenance and Adjustment...
  • Page 206 SERVICE DX210W Items to Check Service Qty. Service Interval 1000 2000 Front Joint Pin (1) Grease F100 Front Joint Pin (2) Grease F100 Swing Bearing Grease Swing Gear and Grease Pinion Swing Reduction Grease Device Swing Reduction Gear Oil 3.8 L Device (80W90) Front Axle...
  • Page 207 SERVICE DATA DX210W Items to Check Service Qty. Service Interval 1000 2000 Front Axle Pin Grease Gear Oil Axle Case (Front) 10.5 L (80w90) Gear Oil Axle Case (Rear) 14 L (80w90) Hub Reduction Gear Oil 2 x 2.5 L Gear Case (80w90) Hub Reduction...

  • Page 208: Maintenance Intervals

    MAINTENANCE INTERVALS SERVICE ITEM PAGE 10 Hour / Daily Service Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear 4-15 Grease Dozer Blade Pins 4-15 Grease Outrigger Pins 4-15 Grease Boom, Arm and Front Attachment Pins (for first 100 hours) 4-15 Check Engine Oil Level 4-16...

  • Page 209: Service Item

    SERVICE ITEM PAGE Check Engine Fan Belt for Cracks, Wear and Correct Tension 4-31 Check Engine Fan Belt Wear 4-32 Change Breaker Filter Element (Optional) 4-33 Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours) 4-33 Replace Full Flow Hydraulic Oil Filter (After First 250 Hours) 4-33 Change Pilot Filter (After First 250 Hours) 4-33...
  • Page 210 Major Parts - Periodic Replacement 4-61 12,000 HOUR / SIX YEAR SERVICE Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) 4-62 ** These checks need to be completed by an authorized DOOSAN dealer. Inspection, Maintenance and Adjustment OP000530 4-14...

  • Page 211: Hour / Daily Service

    10 HOUR / DAILY SERVICE Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear Inflate tires to proper operating pressure for working conditions. See “Tire Changing Procedure” on page 4-87. Grease Dozer Blade Pins Grease every 10 hours for first 100 hours and every 50 hours thereafter.

  • Page 212: Check Engine Oil Level

    Check Engine Oil Level WARNING! Allow the engine to cool before checking the oil level to avoid burns by touching hot engine parts. NOTE: When checking level using a dipstick always remove and wipe it clean before making final level check. FG006593 Figure 13 Shut down engine and wait for 15 minutes.
  • Page 213 Position the machine on firm, level ground. Lower boom and position bucket on ground as shown in Figure 16. Set engine speed to "LOW IDLE." FG006594 Figure 16 Set safety lever to and stand "LOCK" position. Check level gauge by opening right access door. Oil level must be between marks on sight gauge.

  • Page 214: Check For Leaks In Hydraulic System

    Check for Leaks in Hydraulic System Perform a daily walk-around inspection to make sure that the hoses, piping, fittings, cylinders and hydraulic motors are not showing any signs of leakage. If any is noted, determine the source of the leak and repair. Check Fuel Level WARNING! Use extreme safety precautions while refueling to prevent...

  • Page 215: 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 A fuel prefilter is inside the left side access door.
  • Page 216 Remove dipstick (1, Figure 24) and wipe the oil from the dipstick with a cloth. Insert dipstick (1, Figure 24) fully into dipstick tube. FG006599 Figure 24 When dipstick is pulled out, oil level must be between "HIGH" and "LOW" marks on dipstick. NOTE: If oil is above "HIGH"...

  • Page 217: 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. FG006625 Figure 27 WARNING! If using compressed air or water to clean the dust net, make sure that proper eye protection is worn.

  • Page 218: Check Level Of Window Washer Liquid

    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' FG000420 buckets, refer to their specific instructions.

  • Page 219: Check Air Intake System

    Figure 32 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 FG006627 on air intake system.

  • Page 220: Check Operation Of All Exterior Lights, Horn And Control Console Indicator And Monitor

    Check 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 221: Hour / Weekly Service

    50 HOUR / WEEKLY SERVICE Perform All 10 Hour / Daily Service Checks Grease Boom, Arm and Front Attachment 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 greased on a 10 hour / daily basis.

  • Page 222: Grease Swing Bearing

    Arm Link Joint Pin (1 Point) Link Joint Pin (2 Points) Arm Bucket Joint Pin (1 Point) Bucket Link Joint Pin (1 Point) FG003380 Figure 35 Bucket Cylinder Rod Pin (1 Point) FG003381 Figure 36 Grease Swing Bearing There are three grease fittings for the swing bearing. Do not over lubricate.

  • Page 223: Grease Dozer Blade Pin

    Grease Dozer Blade Pin NOTE: Grease it per 10 hours during initial period of 100 hours after buying your new vehicle, after which period grease it per 50 hours. NOTE: In case of performing work underwater, grease it per 10 hours irrespective of elapsed period. Remove chain connecting...

  • Page 224: Grease Front Axle Pin

    Grease Front Axle Pin NOTE: If the unit has been running or working in water the front attachment should be greased on a 10 hour / daily basis. Lower the front attachment to ground. Press the grease fitting and inject grease with the grease gun on the marked point.

  • Page 225: Hour Service

    250 HOUR SERVICE Perform All 10 Hour / Daily and 50 Hour Service Checks Grease Arm and Front Attachment Pins Grease every 10 hours for first 100 hours and every 250 hours thereafter. NOTE: If the unit has been running or working in water the front attachment should be greased on a 10 hour / daily basis.
  • Page 226 Boom Cylinder Head Pin (2 Points) FG008624 Figure 44 Boom Foot Pin (2 Points) Boom Cylinder Rod Pin (2 Points) Arm Cylinder Head Pin (1 Point) FG003391 Figure 45 Boom, Arm Joint Pin (2 Points) FG003393 Figure 46 Arm Cylinder Rod Pin (1 Point) FG003394 Figure 47 Inspection, Maintenance and Adjustment...

  • Page 227: Check Engine Fan Belt For Cracks, Wear And Correct Tension

    Bucket Cylinder Head Pin (1 Point) FG003395 Figure 48 Check Engine Fan Belt for Cracks, Wear 10mm/10kg and Correct Tension COMPRESSOR IMPORTANT ALTERNATOR 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 228: 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. HAAA4030 WARNING! Figure 50 When checking, adjusting or replacing drive belts, care must be taken to prevent accidental cranking of the engine.

  • Page 229: Change Breaker Filter Element (Optional)

    Change Breaker Filter Element (Optional) WARNING! The hydraulic oil will be hot after normal machine operation. Allow the system to cool down before changing pilot filter. Position the machine on firm, level ground. Lover the front FG006644 attachment to the ground and shut down engine. Figure 51 Breaker Filter Loosen the hydraulic oil tank breather cap to release pressure.

  • Page 230: Change Brake Filter (After First 250 Hours)

    Change Brake Filter (After First 250 Hours) NOTE: Replace brake filter after 250 hours on new machine and every 1,000 hours thereafter. (See page 4-49) Inspect Pins and Bushings of Front End Attachments for Signs of Wear Check Fluid Levels in Batteries and Battery Charge Levels Inspect for Any Loose or Missing Nuts and Bolts...

  • Page 231: Hour / 3 Month Service

    500 HOUR / 3 MONTH SERVICE Perform All Daily, 50 and 250 Operating 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 232: Change Engine Oil And Filter

    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 233: Clean Air-Conditioning Outer Filter

    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 234: Check And Clean Air-Conditioning Inner Filter

    Remove filter (Figure 59) and inspect for any damage. Use compressed air to clean filter. If filter is still dirty, then change to new one. Reassemble in reverse order. FG000342 Figure 59 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"...

  • Page 235: Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler And Air Conditioner Condenser Core

    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, FG006639 mask and safety shoes during the cleaning precess. Make Figure 61 sure that all extra personnel are clear of the work area.

  • Page 236: Grease Drive Shaft

    Grease Drive Shaft Front Drive Shaft Front U-joint (1 Point) Front Drive Shaft Spline (1 Point) FG003460 Figure 64 Front Drive Shaft Rear U-joint (1 Point) Center Drive Shaft Front Bearing (1 Point) FG008155 Figure 65 Center Drive Shaft Rear Bearing (1 Point) Rear Drive Shaft Front U-joint (1 Point) FG008156 Figure 66...

  • Page 237: Grease Front Axle Steering Knuckle (2 X 2 Points, 4 Points)

    Grease Front Axle Steering Knuckle (2 X 2 points, 4 points) FG003464 Figure 68 Clean Outer Filter of Air Cleaner 02/05 [MO] 11:30 NOTE: Clean outer filter every 500 hours / 3 months of service. NOTE: If air cleaner clogged warning light (Figure 69) on instrument panel comes "ON"...
  • Page 238 Remove the access cover (2, Figure 71) by loosening the latches (3). Remove the outer filter (4, Figure 71) from the housing. Do not remove inner filter (5). FG003466 Figure 71 Clean the outer filter (4, Figure 71) by blowing compressed air from the inside of the filter towards the outside.

  • Page 239: Change Of Fuel Prefilter

    Change of Fuel Prefilter Open the left 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. FG006640 Figure 74 Remove the bowl using supplied tool.

  • Page 240: Change Fuel Filter

    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. Open the engine cover to access fuel prefilter. FG008158 Figure 77 Position a small container under fuel filter. Unscrew fuel filter from head assembly.

  • Page 241: Drain And Refill Transmission Fluid

    Drain and Refill Transmission Fluid The transmission fluid should be drained and refilled after the first 500 hours of operation and at every 2,000 hours thereafter (See page 4-58) Drain and Refill Hub Reduction Gear Oil The hub reduction gear oil should be drained and refilled after the first 500 hours of operation or rebuild, and every 2,000 hours thereafter.

  • Page 242: Hour / 6 Month Service

    1,000 HOUR / 6 MONTH SERVICE Perform All Daily, 50, 250 and 500 Operating 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 80) from swing reduction device.
  • Page 243 Replace Hydraulic Oil Return Filter 02/05 [MO] 11:30 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 82) on instrument panel comes "ON" the return filter must be serviced.

  • Page 244: Change Pilot Filter

    Change Pilot Filter 02/05 [MO] 11:30 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 85) on instrument panel comes "ON" the pilot filter must be serviced.

  • Page 245: Change Brake Filter

    Change Brake Filter NOTE: Change brake filter after first 250 hours of operation or rebuild, and every 1,000 hours thereafter. WARNING! The hydraulic oil will be hot after normal machine operation. Allow the system to cool down before changing brake filter. Position the machine on firm, level ground.

  • Page 246: Change Air-Conditioning Outer Filter

    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 247: Check Air Conditioner Refrigerant

    Remove filter (Figure 92) and replace with new one. Reassemble in reverse order. FG000342 Figure 92 Check Air Conditioner Refrigerant WARNING! Mixing of tobacco smoke and freon is deadly. smoke while servicing recharging air-conditioning system. Run engine at about 1,800 rpm. Operate for a minimum of FG006774 ten minutes to stabilize the system.

  • Page 248: Check And Adjust Engine

    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 249: 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 250: Replace Outer And Inner Air Cleaner Elements

    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 FG000414 Figure 97 2,000 hours of service. NOTE: Replace inner element whenever a new outer element is installed.

  • Page 251: Change Radiator Coolant

    Change Radiator Coolant WARNING! Allow the engine to cool before releasing the radiator cap. Make sure to loosen the cap slowly to release any remaining pressure. Radiator cleaning is performed while the engine is running. Take extreme caution when working on or near a running ARO1760L engine.

  • Page 252: Hydraulic Oil Exchange And Suction Strainer Cleaning

    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: Based on the type of excavating being completed,...
  • Page 253 Drain hydraulic oil from tank into a container capable of holding 200 liters (53 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 disposed of according to local regulations.
  • Page 254 Drain and Refill Transmission Fluid NOTE: The transmission fluid should be drained and refilled after first 500 hours of operation. There after every 2,000 hours of operation. NOTE: The oil level must be checked on level ground. When replacing fluid, only use approved grade transmission fluid.
  • Page 255 Clean the fill plug. Inspect the fill plug O-ring for deterioration or damage and replace if necessary. Reinstall the fill plug. Drain and Refill Rear Axle Case Oil NOTE: The rear axle case oil should be drained and refilled after the first 500 hours of operation and at every 2,000 hours there after.
  • Page 256 Repeat the process for the remaining hubs. 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...

  • Page 257: 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 258: Hour / Six 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 can not be stored more than 2 years before being discarded or installed on a machine.

  • Page 259: 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 260: Inspection Of Bolt And Nut Tightening Elements

    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 Torque Bolt Point to be Inspected Qty.

  • Page 261: Pump Side

    Joint Bolt with Engine Mounting Bracket and Engine 1) Pump Side • Tool : 24 mm ( • Torque : 27 kg•m FG006787 Figure 114 2) Fan Side • Tool : 17 mm ( • Torque : 6.5 kg•m FG006788 Figure 115 Joint Bolt &...

  • Page 262: Radiator Mounting Bolt 16 4 24 27 264

    Radiator Mounting Bolt • Tool : 24 mm ( • Torque : 27 kg•m FG006791 Figure 118 Tightening Bolt for Hydraulic Oil Tank • Tool : 24 mm ( • Torque : 27 kg•m FG006792 Figure 119 Tightening Bolt for Fuel Tank •...

  • Page 263: Tightening Bolt For Control Valve

    Tightening Bolt for Control Valve • Tool : 19 mm ( • Torque : 11 kg•m FG006796 Figure 122 Tightening Bolt for Swing Reduction Device • Tool : 30 mm ( • Torque : 35 kg•m FG006797 Figure 123 Tightening Bolt for Swing Motor •...

  • Page 264: Joint Bolt With Cab Mounting Rubber And 11 Frame 10 20 17 6.5 64

    11. Joint Bolt with Cab Mounting Rubber and Frame • Tool : 17 mm ( • Torque : 6.5 kg•m FG000454 Figure 126 Joint Bolt with Cab Mounting Rubber and Cab • Tool : 24 mm ( • Torque : 21 kg•m FG000455 Figure 127 12.

  • Page 265: Tightening Bolt For Rear Axle

    13. Tightening Bolt for Rear Axle • Tool : 36 mm ( • Torque : 95 kg•m FG003452 Figure 130 14. Tightening Bolt for Propeller Shaft • Tool : 14 mm ( • Torque : 7 kg•m FG008167 Figure 131 15.

  • Page 266: Tightening Bolt For Center Joint

    17. Tightening Bolt for Center Joint • Tool : 19 mm ( • Torque : 11 kg•m FG003456 Figure 134 18. Tire Wheel Nut • Tool : 32 mm ( • Torque : 55 ~ 60 kg•m FG003457 Figure 135 19.
  • Page 267 21. Tightening Bolt for Lower Attachment 1) Front • Tool : 36 mm ( • Torque : 95 kg•m FG006802 Figure 138 Front Attach 2) Rear • Tool : 36 mm ( • Torque : 95 kg•m FG006803 Figure 139 Rear Attach OP000530 Inspection, Maintenance and Adjustment 4-71...

  • Page 268: 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 269 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 damaged, replacement is necessary. FG006427 Figure 142 Roll old O-ring (1, Figure 143) onto boss (2) around bucket pin (3).
  • Page 270 Roll new O-ring (1, Figure 145) into O-ring groove. FG006430 Figure 145 Inspection, Maintenance and Adjustment OP000530 4-74...

  • Page 271: 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 272 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 273 CAUTION! Before replacing a fuse, be sure to turn starter switch to "O" (OFF) position. Fuse Boxes There are two fuse boxes (Figure 149) on the left side of the heater box. The fuses prevent electrical devices from overloading or shorting. A decal attached to the inside of the fuse box's cover indicates the function and amperage of each fuse.
  • Page 274 Fuse Identification Fuse Box (1) Fuse Box (2) FG009158 Figure 146 Fuse Box (1) Fuse Box (2) Name Capacity Name Capacity Transmission Lever Gauge Panel/Press. Sensor Aux. Mode Switch/Check Reverse Solenoid Connector Forward/Cruise Solenoid Working Lamp Pilot Cut Off/Ram Lock/ Stop Lamp Inching/Hi/Low Solenoid Forward/Reverse/Cruise...

  • Page 275: 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 276 (extended life antifreeze) does. Ethylene glycol is also very hazardous to the environment, people and animals. DOOSAN recommends that ethylene glycol be replaced with propylene glycol. The newer propylene glycol antifreeze comes in many different colors.

  • Page 277: Fuel Transfer Pump (Option)

    FUEL TRANSFER PUMP (OPTION) 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 278 IMPORTANT If there are any sign of leakage while operating transfer pump, inspect the following components to prevent any fires or hazardous fuel spills. • Check all hoses leading to and from the transfer pump. • Check all hose clamps. •...
  • Page 279 Remove strainer cap (4, Figure 151) from strainer (3) on end of inlet hose (5). NOTE: Keep strainer cap (4, Figure 151) in a safe location to reseal strainer (3) after refueling is complete. Insert inlet hose (5, Figure 151) into refueling tank. Turn fuel pump switch (Figure 152) inside of battery box on front side to "I"...

  • Page 280: 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 281 Brake Accumulator Release Brake Accumulator Pressure Using the following procedure; Position the machine on firm, level ground. Lower the front attachment to the ground. Set parking brake switch to the "I" position. This will ensure that the parking brake is "APPLIED". FG006782 Figure 154 Set safety lever and stand on "LOCK"...

  • Page 282: Tires And Wheels

    Do not service or change tires and rims unless properly trained and equipped. Contact your nearest DOOSAN loader dealer or tire manufacturer's local dealer for tire servicing or changing. WARNING! Overheated tire may explode causing serious injury or death.
  • Page 283 If the following defects are found in tires, for safety reasons the Tread tires should be replaced with new tires. For the replacement contact DOOSAN loader dealer or a tire Side Walls manufacturer's local dealer. Breakers • Bead wire is broken or bent, or the tire is greatly Carcass deformed.
  • Page 284 Park machine on secure and level ground able to support weight of machine. Using a jack rated for weight of machine, raise machine to a height so that tires have enough clearance. Place appropriate stands under frame to support machine. Lower bucket to ground.
  • Page 285 Place the tire set (outer and inner tires) on flat ground surface and remove outer and inner tire assembly bolts(4). FG003433 Figure 162 Remove rubber spacer (5) and check any damage of all parts so as to replace part to a new one if there are wear and damage.
  • Page 286 10. Assemble tire set (outer and inner tires) to axle hub (3) while taking heed to assembly bolt holes (6). Whence take care so that tire assembly bolt (4) may not be damaged by axle hub (3). FG003437 Figure 166 11.

  • Page 287: 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. With the engine stopped, remove vent plug (Figure 169) to see if any oil is present.
  • Page 288 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. Shut down engine. Disconnect drain hose and fill swing motor case with hydraulic oil.
  • Page 289 Air Ejection of Brake Line Front Axle IMPORTANT Use a transparent vinyl hose for air ejection. Do not push the brake pedal fully after opening the breeder. Run the engine at low rpm. Rear Axle Open the brake breeder at axle. Push the brake pedal slowly to drain hydraulic oil.

  • Page 290: Maintenance In Special Conditions

    MAINTENANCE IN SPECIAL CONDITIONS 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 291: Long Term Storage

    LONG TERM STORAGE Perform the following if storing the excavator for more than one month. Conditions Maintenance Required Cleaning Pressure wash the undercarriage and track assemblies. Inspect for damage or loose or missing parts. Lubrication Perform all daily lubrication procedures. Apply a coating of light oil to the exposed plated metal surfaces, such as hydraulic cylinder rods, etc.
  • Page 292 Inspection, Maintenance and Adjustment OP000530 4-96...

  • Page 293: Transportation

    Special approval or permits may be required. 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 294: Short Distance Self-Powered Travel

    SHORT DISTANCE SELF-POWERED TRAVEL Follow the Travel Instructions in Section 3 of this manual. Make sure to engage the Swing Lock pin to secure the upper frame assembly before traveling more than a very short distance. (See “Swing Lock Pin and Mechanism” on page 2-76.) If you have to travel across a bridge, make sure that its capacity is rated for the weight of the machine and that it is...

  • Page 295: Trailer Loading/Unloading Procedures

    TRAILER LOADING/UNLOADING PROCEDURES Make sure that the trailer is parked on a firm and level surface. (See Figure 2.) Make sure that the ramps that are being used are designed to handle the weight of the excavator. If required, add blocking under the ramp to provide additional support.
  • Page 296 Set safety lever and stand on "LOCK" position. Set parking brake switch to the "I" position and ram Cylinder toggle switch in the "LOCK" position. FG002254 Figure 6 Shut down engine by turning key to "O"(OFF) position (Figure 5). Remove key from starter switch. FG000175 Figure 7 10.

  • Page 297: Troubleshooting

    If a problem occurs, use the following troubleshooting table to isolate the cause and take necessary measure(s) for adjustment and repair. If the cause of the problem cannot be isolated, consult with your nearest DOOSAN service center for assistance. Never attempt...
  • Page 298 Refill. surges. Clogged air intake system. Clean system and replace filter. Injection pump out of adjustment. Contact your DOOSAN dealer. Clogged fuel filter. Replace fuel filter. Water or dirt in fuel system. Clean system and add new fuel. Clogged or dirty fuel injectors.

  • Page 299: Hydraulic System

    HYDRAULIC SYSTEM Problem Cause Remedy None of the controls function (loud Hydraulic pump failure. Contact your DOOSAN dealer. noise from pumps) Low hydraulic oil level. Add hydraulic oil as required. Suction line clogged or damaged. Clean or replace as required.

  • Page 300: Swing System

    SWING SYSTEM Problem Cause Remedy No swinging motion Swing brake valve faulty. Replace brake valve. Hydraulic timer faulty. Replace timer. Low brake release pressure. Adjust pressures. Swing motor failed. Replace swing motor. Remote control valve failed. Replace control valve. Wrong pilot line connection. Reconnect pilot lines.

  • Page 301: Travel System

    Problem Cause Remedy Working mode selector does not Blown fuse. Replace fuse. work Connector failure. Replace connector. Wiring harness damaged. Repair or replace as required. e-EPOS controller failure. Replace as required. TRAVEL SYSTEM Problem Cause Remedy Travel motion does not function Axle failure Repair Activate the emergency actuation...

  • Page 302: Steering

    Problem Cause Remedy Gear will not change Bent or unbalanced drive shaft Repair or exchange Loose universal joint Tighten Substantial wear of spline Exchange Spider bearing worn Exchange Lack of grease Lubricate Noise from axle Excessive gear wear Exchange Damage to gear Exchange Lack of gear oil Refill...

  • Page 303: Brakes

    BRAKES Problem Cause Remedy Brakes not working Brake pressure is too low Repair or exchange Brake pump failure Repair or exchange Brake disks worn Exchange or adjust clearance Burned out brake disks Exchange Refill N gas or exchange Accumulator gas leaking Air in brake lines Bleed air Brake oil leakage...
  • Page 304 Troubleshooting OP000440...

  • Page 305: Specification

    OP000531 Specification SPECIFICATION One-Piece Boom (5.2 m Boom, 2.6 m Arm, Front Dozer, Rear Outrigger) Specification Component Metric English Equipment Weight 18.8 metric tons 20.7 tons Bucket CECE 0.70 m 0.92 yd PCSA 0.80 m 1.05 yd Engine Model DL06 Type Water Cooled - 6 Cylinders Rated Output...
  • Page 306 Two-Piece Boom (5.36 m Boom, 2.6 m Arm, Front Dozer, Rear Outrigger) Specification Component Metric English Equipment Weight 19.3 metric tons 21.3 tons Bucket CECE 0.70 m 0.92 yd PCSA 0.80 m 1.05 yd Engine Model DL06 Type Water Cooled - 6 Cylinders Rated Output 158 ps @ 1,900 rpm 158 ps @ 1,900 rpm...

  • Page 307: Overall Dimensions

    OVERALL DIMENSIONS One-Piece Boom FG008699 Figure 1 Dimension Reference Description 5.2 m (17' 1") One-Piece Boom 2.2 m (7' 3") Arm 2.6 m (8' 6") Arm 3.1 m (10' 2") Arm Shipping Length 8,715 mm 28' 7" 8,659 mm 28' 5" 8,507 mm 27' 10"...
  • Page 308 Two-Piece Boom FG008700 Figure 2 Dimension Reference Description 5.36 m (17' 7") Two-Piece Boom 2.3 m (7' 7") Arm 2.6 m (8' 6") Arm Shipping Length 8,860 mm 29' 1" 8,610 mm 28' 3" Shipping Width 2,496 mm 8' 2" 2,496 mm 8' 2"...

  • Page 309: Working Range

    WORKING RANGE One-Piece Boom FG008672 Figure 3 Dimension Reference Description 5.2 m (17' 1") One-Piece Boom 2.2 m (7' 3") Arm 2.6 m (8' 6") Arm 3.1 m (10' 2") Arm Max. Digging Reach 8,830 mm 28' 11" 9,200 mm 30' 2"...
  • Page 310 Two-Piece Boom FG008673 Figure 4 Dimension Reference Description 5.36 m (17' 7") Two-Piece Boom 2.3 m (7' 7") Arm 2.6 m (8' 6") Arm Max. Digging Reach 9,230 mm 30' 3" 9,530 mm 31' 3" Max. Digging Depth 5,600 mm 18' 4"...

  • Page 311: Index

    1INDEX Numerics 4-46 2-61 1,000 Hour / 6 Month Service Cabin Light 4-15 2-71 10 Hour / Daily Service Cabin Storage Compartments 4-62 2-15 12,000 Hour / Six Year Service Cabin Work Light Switch 4-53 2-67 2,000 Hour / Yearly Service Ceiling Cover 4-29 4-33...
  • Page 312 4-52 4-93 Check and Adjust Engine General Venting 2-31 4-29 Check Warning Light Grease Arm and Front Attachment Pins 2-28 4-15 Coolant Temperature Gauge Grease Dozer Blade Pins 2-30 4-15 Coolant Temperature Warning Light Grease Outrigger Pins 2-74 Cover 2-11 Emergency Stop Switch 4-31, 4-32 Fan Belt...
  • Page 313 4-15 4-54 of Damage or Abnormal Wear Outer Air Cleaner Element 4-41 Inspecting Engine Before Starting Outer Element of Air Cleaner Inspection, Maintenance and Adjustment Overall Dimensions 2-20, 2-26 2-52 Instrument Panel Overload Alarm Selection 2-17 Overload Warning Switch (Optional) 2-43 Language 4-19...
  • Page 314 2-64 4-92 Adjusting Reclining Motor 2-63 4-19, 4-46, 4-53 Adjusting the Seat Forward Reduction Device 2-63 4-33 Adjusting the Seat's Angle Reduction Device Oil 2-64 Adjustment of Lumbar Support System 2-66 Air Suspension Seat Switches 2-64 2-39 Angle Adjustment of Armrest Auto Idle Selector Button 2-64 3-38...
  • Page 315 2-38 Trenching Mode Selector Button Troubleshooting 2-17 Warning Light Switch 4-19 Water Separator 2-76 Wheel Chocks 4-22 2-40 Window Washer Liquid Up Arrow Button Windows 2-73 Door Window Holder 2-68 Front 4-91 Venting and Priming Hydraulic System 2-69 Front Bottom 4-93 General Venting 2-68...

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