Doosan DX220A Operation And Maintenance Manual
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Doosan DX220A Operation And Maintenance Manual

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DX220A
DX225LCA
Operation and Maintenance Manual
K1049155AE
Serial Number 11707 and Up
August 2012
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.
K1049155AE Operation and Maintenance Manual
Copyright Doosan 2012

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Summary of Contents for Doosan DX220A

  • Page 1 Serial Number 11707 and Up August 2012 DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products.

  • Page 3: Table Of Contents

    Table of Contents Safety..................1-1 To the Operator of a DOOSAN Excavator ......... 1-1 Location of Safety Labels..............1-5 Summary of Safety Precautions for Lifting in Digging Mode.... 1-14 Unauthorized Modifications.............. 1-15 General Hazard Information............. 1-15 Before Starting Engine..............1-24 Machine Operation................1-27 Maintenance ..................
  • Page 4 Ceiling Cover ................... 2-58 Front Windows ................. 2-59 Door Side Latch ................2-61 Cabin Storage Compartments ............2-62 Ashtray..................... 2-62 Sun Visor ..................2-63 Hanger ..................... 2-63 Cup Holder..................2-64 Door Window Holder................ 2-64 Emergency Glass Breaking Tool ............. 2-64 Miscellaneous Access Covers and Doors........
  • Page 5 10 Hour / Daily Service ..............4-14 50 Hour / Weekly Service ..............4-23 250 Hour / Monthly Service.............. 4-26 500 Hour / 3 Month Service ............. 4-33 1,000 Hour / 6 Month Service ............4-41 2,000 Hour / Yearly Service ............. 4-47 4,000 Hour / Biennial Service ............
  • Page 6 Specification ................7-1 Standard Specification ............... 7-1 Overall Dimensions................7-2 Working Range .................. 7-4 Approximate Weight of Workload Materials........7-5 Index ...................8-1 Table of Contents K1049155AE...
  • Page 7 Table of Contents K1049155AE...
  • Page 8 Table of Contents K1049155AE...

  • Page 9: Safety

    OP001759 Safety TO THE OPERATOR OF A DOOSAN EXCAVATOR DANGER Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
  • Page 10 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 sent. If this machine has been purchased in another...
  • Page 11 Learn Signal Words Used with Safety Alert Symbol The words "CAUTION," "WARNING," and "DANGER" used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle,"...
  • Page 12 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 13: Location Of Safety Labels

    LOCATION OF SAFETY LABELS FG014280 Figure 1 There are several specific warning signs on this machine. The exact location of hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning signs. Make sure that all the warning signs are legible. Clean the warning signs or replace the warning signs if you cannot read the words.
  • Page 14 1. Warnings for Operation, Inspection and Maintenance (190-00688, 190-00092) AVOID DEATH OR SERIOUS INJURY. - READ AND UNDERSTAND OPERATION MANUAL AND SAFETY LABELS prior to operating this machine. Never get in under the machine while it is being jacked up with boom and arm.
  • Page 15 3. Warnings When Opening a Front Window (2190-3388, 190-00093) When raising window, lock it in place with lock pins on both sides. Falling window can cause injury. 2190-3388 190-00093 FG000665 4. Warnings for a High-pressure Cylinder (190-00122) 190-00122 ARO1110L Safety OP001759...
  • Page 16 5. Warnings When Adjusting Track Tension (2190-3386A, 190-00521) T h e t r a c k a d j u s t e r a d j u s t m e n t a n d h a n d l i n g The spring in the track adjuster is loaded with great force and the pressure in the cylinder is very high.
  • Page 17 7. Warnings for Batteries Maintenance (2190-2533A, 190-00100) Battery fumes can explode. Keep sparks and flames away from batteries. Always avoid storing metals like tools or flammable materials around or on the batteries. Explosion or fire can be caused by shortcircuiting batteries. Surfuric acid in battery is poisonous.
  • Page 18 9. Warnings for Hot Coolant (190-00692, 190-00097) HOT COOLANT CAN CAUSE INJURY OR BLINDNESS. Never loosen or open radiator cap when coolant is hot and under pressure. To open cap, stop engine, wait until radiator is cool. Then loosen cap 190-00097 slowly to relieve the pressure.
  • Page 19 11. Warnings for Rotating Parts (190-00694, 190-00095, 190-00557) 190-00095 Rotating parts can cause personal injury. Keep away from fan and belt when engine is run- ning. Stop engine before servicing. 190-00557 190-00694 ARO1190L 12. Warning Tag - Used When Inspection and Maintenance (190-00695A, 190-00098A) WARNING...
  • Page 20 13. Warning for a Hot Surface (190-00648A) 190-00648 ARO1210L 14. Caution for Hood (190-00522A) 190-00522A FG012965 Safety OP001759 1-12...
  • Page 21 15. Keep Out of the Swing Area (2190-3379A, K1008571) 2190-3379A K1008571 FG006551 16. Warnings for Front Attachments (190-00652) 190-00652 ARO1230L Safety OP001759 1-13...

  • Page 22: 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. Safety OP001759 1-14...

  • Page 23: 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 24 Inside Operator's Cabin When entering the operator's cabin, always remove all mud and oil from the soles of your shoes. If you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
  • Page 25 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 26 • When driving machine, avoid obstacles excessive rough terrain. Keep the machine on terrain where working and traveling conditions are good. • Remove any large rocks or obstacles. • Fill any ditches and holes. • Provide machines for and schedule time to maintain good terrain conditions.
  • Page 27 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 28 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 29 Reinstallation, recertification and/or replacement of the system may be necessary. Contact your DOOSAN distributor for available safety guards and/or recommendations to prevent danger of getting hit by objects that could strike the operator's cabin. Make sure that all other work site crew members are kept well away from the excavator and safe from possible hazards.
  • Page 30 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 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 31 Emergency Exit The excavator 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 that requires breaking glass to exit from the operator's cabin. Grip the handle firmly and use the sharp point to break the glass.

  • Page 32: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make sure the ground surface is as hard and horizontal as possible before carrying out operations.
  • Page 33 Remember that soil after heavy rain, blasting or after earthquakes, is weakened. Newly laid earth and the soil near ditches is typically loose. It can collapse under the weight of vibration of your machine and cause your machine to tip over. Install the head guard (FOPS) if working in areas where there is a danger of falling rocks.
  • Page 34 Check gauges and monitor displays for normal operation before starting the engine. Listen for unusual noises and remain alert for other potentially hazardous conditions at the start of the work cycle. Do not short-circuit the starting motor to start the engine. This is not only dangerous, but may also damage the machine.

  • Page 35: 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 travel direction from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing travel HAOA190L...
  • Page 36 Travel Precautions TRAVEL POSTURE Never turn the starting switch to the "O" (OFF) position when traveling. It is dangerous if the engine stops while the machine is traveling. It will be impossible to operate the steering. Attachment control levers should not be operated while traveling.
  • Page 37 Traveling on Slopes Never jump onto a machine that is running away to stop it. There is a danger of serious injury. Traveling on slopes could result in the machine tipping over or slipping. On hills, banks or slopes, carry the bucket approximately 20 - 30 cm (8 - 12 in) above the ground.
  • Page 38 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. FG000368 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 39 Precautions for Operation Be careful not to mistakenly travel too close to the edge of a cliff. Use the machine only for its main purpose. Using it for other purposes will cause failures. To ensure a good view, always do the following: •...
  • Page 40 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 (1, Figure 25).
  • Page 41 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 42: Maintenance

    OSHA certified lockout device and a length of chain or cable to keep the safety lever in the fully when performing inspection lowered, nonactive position. Warning tags, for controls are available from DOOSAN 190-00695A distributors. FG012195...
  • Page 43 Proper Tools Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. There is a 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 44 Burn Prevention When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
  • Page 45 Warning for Counterweight and Front Attachment Removal DANGER DOOSAN warns any user, that removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
  • Page 46 Precautions for Removal, Installation, and Storage of Attachments Before starting removal and installation of attachments, decide on the team leader. Do not allow anyone except the authorized workers close to the machine or attachment. Place attachments that have been removed from the machine in a safe place so they do not fall.
  • Page 47 Prevention of Crushing and Cutting You should always have at least two people working together if the engine must be run during service. One person needs to remain in the operator's seat, ready to work the controls or stop the machine and shut off the engine. Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.
  • Page 48 If necessary depending on the type of failure, please contact your DOOSAN distributor for repairs. Precautions with High-pressure Lines, Tubes and Hoses When inspecting or replacing high-pressure piping or hoses, check to verify that pressure has been released from the circuit.
  • Page 49 Waste Materials Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. To prevent pollution of the environment, always do the following: •...

  • Page 50: Battery

    BATTERY Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following: • Do not smoke or bring any flame near the battery. •...
  • Page 51 Boost Starting or Charging Engine Batteries If any mistake is made in the method of connecting the booster cables, it may cause an explosion or fire. Always do the following: • Turn off all electrical equipment before connecting leads to the battery. This includes electrical switches on the battery charger or boost starting equipment.

  • Page 52: Towing

    Shackle • If the engine on the problem machine will not start or there is a failure in the brake system. always contact your DOOSAN distributor. Towing Wire FG000669 • Never go between the towing machine and the towed Figure 45 machine during the towing operation.

  • Page 53: Shipping And Transportation

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

  • Page 54: Excavator Rated Lift Capacity Tables

    EXCAVATOR RATED LIFT CAPACITY TABLES WARNING Let everybody be away from the boom cylinder. While lifting operation, boom, arm, bucket hoses might burst and then high-pressure oil will be ejected at high speed. If that failure mode takes place, handling weight or front structure might fall by its gravity to the ground to cause fatal injury to the person.
  • Page 55 Avoid traveling with a suspended load. Before swinging (or if required, traveling), bring the load into an arm position (radius and height) that has a safer weight capacity rating and adequate movement clearance. The operator and all work site personnel should be thoroughly familiar with safety instructions and procedures within this Operation and Maintenance Manual.
  • Page 56 DX220A Track Width : 2.8 m (9’ 2") STD Track Boom : 5.7 m (18’ 8") : 2.4 m (7’ 10") Bucket : SAE 1.05 m (CECE 0.92 m Counterweight : 3,800 kg (8,378 Ib) Shoe : 600 mm (24")
  • Page 57 DX220A Track Width : 2.8 m (9’ 2") STD Track Boom : 5.7 m (18’ 8") : 2.9 m (9’ 6") Bucket : SAE 0.92 m (CECE 0.81 m Counterweight : 3,800 kg (8,378 Ib) Shoe : 600 mm (24")
  • Page 58 DX225LCA Track Width : 2.99 m (9’ 10") LC Track Boom : 5.7 m (18’ 8") : 2.4 m (7’ 10") Bucket : SAE 1.05 m (CECE 0.92 m Counterweight : 4,100 kg (9,039 Ib) Shoe : 600 mm (24") : Rating Over Front : Rating Over Side or 360 degree Unit...
  • Page 59 DX225LCA Track Width : 2.99 m (9’ 10") LC Track Boom : 5.7 m (18’ 8") : 2.9 m (9’ 6") Bucket : SAE 0.92 m (CECE 0.81 m Counterweight : 4,100 kg (9,039 Ib) Shoe : 600 mm (24") : Rating Over Front : Rating Over Side or 360 degree Unit...
  • Page 60 DX225LCA Track Width : 2.99 m (9’ 10") LC Track Boom : 5.7 m (18’ 8") : 3.5 m (11’ 6") Bucket : SAE 0.81 m (CECE 0.72 m Counterweight : 4,100 kg (9,039 Ib) Shoe : 600 mm (24") : Rating Over Front : Rating Over Side or 360 degree Unit...

  • Page 61: Operating Controls

    OP001760 Operating Controls The "Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-2 “Operator's Area” on page 2-4 “Operational Controls and Panels” on page 2-6 “Instrument Panel” on page 2-19 “Multifunction Gauge Graphic Information” page 2-25 “Mode Selector Buttons”...

  • Page 62: Component Locations

    COMPONENT LOCATIONS FG014178 Figure 1 Operating Controls OP001760...
  • Page 63 Reference Reference Description Description Number Number Counterweight Hood Bucket Cylinder Muffler Guide Link Hydraulic Oil Tank Bucket Fuel Tank Push Link Engine Tooth Point Fuel Tank Fill Cap Side Cutter Radiator and Oil Cooler Idler Control Valves Track Adjuster Swing Motor Track Guide Air Cleaner Battery...

  • Page 64: Operator's Area

    OPERATOR'S AREA FG001346 Figure 2 Operating Controls OP001760...
  • Page 65 Reference Reference Description Description Number Number Instrument Panel Storage Compartment (See page 2-19) (See page 2-62) Cigarette Lighter Heater and Air Conditioner Unit (See page 2-15) Stereo Ashtray (See page 2-51) (See page 2-62) Fuse Box Travel Levers (See page 2-53) (See page 3-15) Left-hand Work Lever (Joystick) Right-hand Work Lever...

  • Page 66: Operational Controls And Panels

    OPERATIONAL CONTROLS AND PANELS 12 11 10 9 8 FG001363 Figure 3 Operating Controls OP001760...
  • Page 67 Reference Reference Description Description Number Number Starter Switch Wiper Control Panel Engine Speed Control Dial Cigarette Lighter Quick Clamp Switch (Optional) Power Socket For 12v Auxiliary Mode Switch Travel / Swing Alarm Switch (Optional) Engine Emergency Stop Cable Seat Warmer Switch (Optional) Audio Control Panel Horn Button Travel Speed Selector Switch...
  • Page 68 1. Starter Switch A three-position starter switch is used to start or shut down engine for equipment operation. Turning switch to this position turns engine "OFF" with its electrical system. In this position engine is "OFF" but interior cabin light and fuel tank transfer pump (if equipped) are functional.
  • Page 69 2. Engine Speed Control Dial The engine speed is controlled by the dial. Rotating it clockwise increases engine speed (rpm) counterclockwise decreases engine speed. Low idle (Lowest engine speed) High idle (Highest engine speed) NOTE: The auto idle system will automatically reduce engine speed to idle speed approximately four seconds after all of the control levers are in the HAOA690L...
  • Page 70 5. Engine Emergency Stop Cable If the engine does not shut down when using the starter switch, it can be stopped by moving the engine emergency stop cable. See “Engine Speed Control” on page 3-20. 6. Audio Control Panel The audio system can be remotely controlled using this panel.
  • Page 71 Press the down button, to "DECREASE" volume. FG000021 Figure 11 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 button is again SCAN...
  • Page 72 8. Light Switch This switch is used to turn "ON" the lights. In this position, all lights are "OFF." In this position, all illumination lights of the instrument panel and the control switches are turned "ON." In this position, all illumination lights and work lights are turned "ON."...
  • Page 73 11. 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 17 12.
  • Page 74 14. Wiper Control Panel This panel is only for operation of the upper windshield wiper. When the wiper stops running, it moves to right side of the cabin, resting in its support. NOTE: When the front window is lifted, the wiper motor will not operate.
  • Page 75 Windshield Washer Button Pressing the washer button will spray windshield washer fluid onto the windshield. Use only the proper windshield washer fluid in the system. NOTE: Do not operate the windshield washer without any fluid. If operate without any fluid, the washer motor may be damaged.
  • Page 76 17. Travel/Swing Alarm Switch (Optional) If unit is equipped with a travel/swing alarm buzzer, push this switch to active it, whenever swinging or traveling. In this position, the travel/swing alarm system is turned "OFF." In this position, the travel alarm will only sound, when the machine is moving.
  • Page 77 20. Rotating Buttons For a machine equipped with an attachment that rotates, press the upper two buttons on the top of the left-hand work lever (joystick) to rotate the attachment clockwise or counterclockwise. Left button is for counterclockwise and the right one is for clockwise. WARNING FG000382 Before using any attachment in a work application, be...
  • Page 78 23. Instrument Panel CHECK See “Instrument Panel” on page 2-19. 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO FG014201 Figure 32 24. Safety Lever See “Safety Lever” on page 3-13. FG000038 Figure 33 25. Photo Sensor The photo sensor detects the radiant energy of the sun. In auto mode the air conditioner will automatically adjust the air temperature based on to the detected radiant energy.

  • Page 79: Instrument Panel

    INSTRUMENT PANEL CHECK 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO FG014202 Figure 35 Reference Reference Description Description Number Number Fuel Gauge Work Light Indicator Light Engine Coolant Temperature Power Mode Selector Button Gauge (See page 2-30) Hydraulic Oil Temperature Gauge Auto Idle Selector Button (See page 2-30) Multifunction Gauge and Graphic...
  • Page 80 Functional check When the engine starter switch is turned to the "I" (ON) position, all gauge bands, switch/button indicator lights and warning lights will turn "ON" and the alarm buzzer will sound about two seconds. During this functional check, a LOGO will appear on the multifunction gauge in the graphic information area (3 and 4, Figure 35).
  • Page 81 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 82 4. Multifunction Gauge and Graphic Information Area 02/05 [MO] 11:30 See “Multifunction Gauge and Graphic Information” on page 2-25. This section will have a more in-depth explanation of the display area. E/G SPEED FG000043 Figure 39 5. Digital Clock A digital clock, shows the current time. The displayed contents are as follows.
  • Page 83 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 84 10. Engine Check Warning Light (Not Used) CHECK FG000045 Figure 45 11. Preheating Indicator Light In cold weather this light indicates that the engine preheat function is operating. When this indicator light turns "OFF," it means that engine preheat cycle has been completed. HAAE2000 Figure 46 12.

  • Page 85: Multifunction Gauge And Graphic Information

    MULTIFUNCTION GAUGE AND GRAPHIC INFORMATION When the engine starter switch is turned to the "I" (ON) position, a LOGO will appear on the display screen for about two seconds. 02/05 [MO] 11:30 When the LOGO disappears, the multifunction gauge and graphic information screen will appear.
  • Page 86 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 87 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 53 Rear Hydraulic Pump Pressure The rear pump pressure is numerically displayed.
  • Page 88 Examples of Warning Display 02/05 [MO] 11:30 02/05 11:30 1700 E/G SPEED E/G SPEED E/G SPEED FG000059 FG000060 FG000061 <2 kinds of warning display> <4 kinds of warning display> <6 kinds of warning display> Figure 56 Hydraulic Oil Overheat Warning If the hydraulic oil temperature is too high, this symbol appears on the screen.
  • Page 89 Return Filter Clogged Warning This symbol indicates when the hydraulic return filter is clogged. If this symbol is displayed, immediately stop operation and replace the return filter. After the return filter has been serviced, restart machine operation to remove the warning symbol. FG000054 Figure 60 Air Cleaner Clogged Warning...

  • Page 90: Mode Selector Buttons

    MODE SELECTOR BUTTONS Power Mode Selector Button POWER Auto Idle Selector Button AUTO Flow Control Button FG014203 Figure 63 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 91 3. Flow Control Button When the button is pushed, you can control the hydraulic oil flow rate. The flow control button is used to set the flow rate of pump match the installed tool/attachment for optimal performance, without damaging it. NOTE: For further details, see “Flow Control”...

  • Page 92: Setting Main Menu

    SETTING MAIN MENU By using a combination of the selector buttons (Figure 68), 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 67...
  • Page 93 2. Down Arrow Button Down arrow button ( ), is used to move a menu item "Down" or to the "Right." FG000069 Figure 70 3. Display Selector Button (ESC - Escape) Display selector button ( ), is used to change the displayed information on the screen.
  • Page 94 Display Selection and Escaping Display Selection When the display button (Figure 73) is pressed for more than three seconds, the main menu screen (Figure 75) 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 95 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 96 '00' Minute Setting SE T CLO C K 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 97 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 82 Filter / Oils Operating Hour Reset FILTER / OIL INFO After changing a filter or oil, reset the operating hour to zero (Hrs: 0000).
  • Page 98 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 99 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 100 Select adoption (lock) or nonadoption (unlock) at set : UP : DOWN : SELECT password menu. FG000229 NOTE: Keep in mind never to forget password. Figure 89 NOTE: Please contact a DOOSAN distributor, if you forget your password. Operating Controls OP001760 2-40...

  • Page 101: 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 90...
  • Page 102 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 103: 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 96 Breaker Selection 02/05 [MO] 11:30 E/G SPEED FG000258 Figure 97 Shear Selection 02/05 [MO] 11:30 E/G SPEED FG000259 Figure 98...
  • Page 104 Overload Alarm Selection (Optional) 02/05 [MO] 11:30 E/G SPEED FG000260 Figure 99 Quick Clamp Operation Selection (Optional) 02/05 [MO] 11:30 E/G SPEED FG000388 Figure 100 Operating Controls OP001760 2-44...

  • Page 105: Heater And Air Conditioner Control Panel

    HEATER AND AIR CONDITIONER CONTROL PANEL Location of Controls and Vents FG000288 Figure 101 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 106 Control Panel OUTSIDE AUTO AUTO TEMP MODE FG000086 Figure 102 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 107 Off Button This button is used to stop the fan and air conditioner. FG000089 Figure 104 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 108 Used to direct air flow to upper portion of operator's cabin from both the front and rear. FG000099 Figure 108 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 109 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 cabin. The select mode is displayed on the LCD.
  • Page 110 Defroster Button Used to direct air flow to front window. FG000106 Figure 116 10. LCD Display This display shows the current setting. OUTSIDE AUTO FG000107 Figure 117 Memory Function The air conditioner panel has a memory function. When the starter switch is turned "OFF" the settings for the panel, will be stored.

  • Page 111: Stereo

    STEREO Before operating the stereo or CD player, read operation manual enclosed with stereo. Stereo PROGRAM TUNE FG000108 Figure 118 Reference Reference Description Description Number Number Power / Volume Control Preset Station Sound Mode Selector Tape Ejection Band Selection Fast Forward / Rewind Tuning Up / Down Tape Loading Slot Scan Function / Auto Store...

  • Page 112: Miscellaneous Electrical Devices

    MISCELLANEOUS ELECTRICAL DEVICES Cabin Light A light is installed on the top of the operator's cabin. 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 120 Pilot Cutoff Switch...
  • Page 113 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 124) on the left side of the heater box.

  • Page 114: 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 115 4. Reclining Position Adjustment Pulling up the right lever (4,Figure 125) 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 116 8. Seat Belt WARNING The seat belt is for the operator's safety and should always be worn. Before driving the machine, adjust the seat to the desired position for maximum comfort and machine control, then fasten the seat belt. Seat belts must be worn across the pelvic region and adjusted snugly to lessen the chance and severity of injury in case of an accident.
  • Page 117 9. Seat Back-pocket The seat has a seat back pocket. It is used for storing the Operation And Maintenance Manual. 10. Left and Right Control Stand Adjustment For operator's convenience, the right and left control stands and seat can slide together, within a 160 mm (6.3 in) forward or backward travel distance.

  • Page 118: Ceiling Cover

    CEILING COVER NOTE: If 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.

  • Page 119: Front Windows

    FRONT WINDOWS WARNING When leaving operator's seat, set safety lever to "LOCK" position (Figure 134), if not a serious accident could occur by accidentally moving the work levers. Front Upper Window FG000189 The front upper window can be housed in the cabin's ceiling. Figure 134 Opening the Window WARNING...
  • Page 120 Closing the Window WARNING Be careful that your hands are not caught in window frame. Lower bucket to ground. Set safety lever (Figure 134) on "LOCK," and shut down engine. FG000193 Figure 136 Holding upper handles (1, Figure 136) of front window with left and right-hand, pull lock levers (2, Figure 136) to release the lock.

  • Page 121: Door Side Latch

    DOOR SIDE LATCH The door side latch (1, Figure 139) is used to secured door to side of cabin when it is opened. NOTE: Keep door closed and locked when machine is not in use. FG000196 Figure 139 To release door from side of cabin, push latch lever (2, Figure 140) down.

  • Page 122: Ashtray

    CABIN STORAGE COMPARTMENTS There are two storage compartments behind the operator's seat. The large compartment (1, Figure 141) is for storing nonperishable items. The covered other one (2, Figure 141) is interconnected with the air conditioner. It can be supplied with either warm or cool air when air conditioner is turned "ON."...

  • Page 123: 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 144) down. When not wanting protection, hold bar with left-hand and push release button (2, Figure 144) with right-hand.

  • Page 124: Cup Holder

    CUP HOLDER There is a cup holder on the right side of the cabin (1, Figure 148). Open the access cover and lower it to a horizontal position. FG000205 Figure 148 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 149) against the window.

  • Page 125: Miscellaneous Access Covers And Doors

    MISCELLANEOUS ACCESS COVERS AND DOORS Side Door Open the side access door and slide prop rod (1, Figure 151) in slot (2) until it locks at end of slot. FG000165 Figure 151 Battery Box Door Opening Open door until locking device (1, Figure 152) latches. Closing While holding door, press locking device to release lock and close door.
  • Page 126 Operating Controls OP001760 2-66...

  • Page 127: Operation

    Operation TO HANDLE A NEW EXCAVATOR All DOOSAN excavators are inspected and adjusted before leaving the factory. However, it is required that 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 128: Starting And Stopping The Engine

    Lubrication and Filters Change engine oil and replace oil filter after first 50 hours of operation. Change swing reduction device oil after first 250 hours of operation. Change hydraulic oil return filter after first 250 hours of operation. Replace travel and reduction gear oil after first 250 hours of operation.
  • Page 129 Operational Checks Before Starting Engine WARNING When leaving operator's seat, set the safety lever to "LOCK" (Figure 1) position, if not a serious accident could occur by accidentally moving the travel or work levers. FG000211 Figure 1 Set safety lever on "LOCK" (Figure 1). Fasten seat belt.
  • Page 130 Engine Start WARNING Start the engine after sounding horn and making sure that there are no people or obstacles in the area. Perform all steps in “Operational Checks Before Starting Engine” on page 3-3. Set engine speed control dial slightly above "LOW IDLE" (Figure 3).
  • Page 131 After warming unit, check all operating indicators to make sure that all engine systems (oil pressure, coolant, etc.) are in the normal operating range. If any problems are noticed, shut down engine. Normal indicators are: CHECK 02/05 [MO] 11:30 1700 E/G SPEED FG000092 Figure 6...
  • Page 132 Cold Weather Starting WARNING DO NOT USE STARTING FLUIDS. The preheat system could cause the starting fluid to explode. Starting fluids should never be used. Perform all steps in "Operational Checks Before Starting HAOB34L Engine." Figure 7 Set engine speed control dial slightly above "LOW IDLE" (Figure 7).
  • Page 133 After engine has started, release key. Key will return to the "I" (ON) position (Figure 10). After the engine starts, check all operating indicators to make sure that all engine systems (oil pressure, coolant, etc.) are in the normal operating range. If any problems are noticed, shut down engine.
  • Page 134 Connecting the Booster Batteries Shut down engine of the machine on which booster batteries (3, Figure 12) are mounted. Connect one end of red cable (1, Figure 12) to the positive (+) terminal of the machine batteries (4), and the other end to the positive (+) terminal of the booster batteries.
  • Page 135 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 136 Hydraulic System Warm-up – Cold Weather Run engine at "LOW IDLE" (no load) for five minutes (Figure 16). HAOB290L Figure 16 Run engine for approximately five minutes set at the middle of the speed range, without a load (Figure 17). HAOB410L Figure 17 Set safety lever (1, Figure 18) on "UNLOCK"...
  • Page 137 Set engine speed control dial to "HIGH IDLE" (Figure 20). Repeat Step 4 for five minutes. If working speeds continue to be slow, continue to operate, but use extreme caution because the machine function may be erratic. Check for clearance and fully raise the front attachment. Slowly swing clockwise 3 revolutions.
  • Page 138 Shut down engine by turning key to "O" (OFF) position (Figure 24). Remove key from starter switch. FG001372-3 Figure 24 Check and Confirmation After Stopping Engine Repair excavator, if there are any coolant or oil leaks. Inspect front attachment and under carriage for abnormal appearances.

  • Page 139: 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 140: Travel

    TRAVEL WARNING Before operating the travel levers, make sure that you know in which direction the machine is pointing. Look at the end of the track assemblies. If the drive motors are visible while sitting in the operator's seat, you are looking at the back end of the track assembly (therefore, you are looking backwards).
  • Page 141 Travel Control Lever Operation To travel straight (Figure 27), push both travel control levers/pedals fully forward or backwards. The farther the levers/pedals are pressed, the faster the travel speed. NOTE: "X" is the sprocket end of the track. "X" FG000303 Figure 27 Pivot turns (Figure 28) are made by rotating only one track forward or backward.
  • Page 142 General Travel Instructions Set engine speed control dial (Figure 31) on desired speed. HAOB550L Figure 31 Set safety lever on "UNLOCK" position, and folding the front, raise it 40 - 50 cm (16 - 20 in) above ground. See Figure 32. 40 ~ 50 cm FG000123 Figure 32...
  • Page 143 WARNING When traveling, keep bucket from 20 - 30 cm (8 - 12 in) above ground. Do not travel backward on a slope. Never turn or travel crosswise on a slope. Choose a safe alternate route before climbing a slope. FG000212 If excavator starts to slip or becomes unstable, lower Figure 34...
  • Page 144 Make sure that the material buildup has been cleared. See Figure 37 and Figure 38. The excavator can travel in water that comes up to center of upper carriage rollers. Make sure that footing is solid so that the machine will not sink. See “Working in Water” on page 3-31.
  • Page 145 Operation OP001761 3-19...

  • Page 146: 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. Park on firm, level ground. Lower bucket to ground. Set safety lever on "LOCK" position.
  • Page 147 11. On the rear of left control stand in cabin is a vernier caliper throttle control. The throttle control is a push/pull and/or screw type assembly. The locking collar (7, Figure 44) at base of mechanism must be turned to the released position before the throttle can be adjusted.
  • Page 148 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 149 Boost Mode Power boost switch is used to gain maximum digging force. The power boost is activated while the lower button is being pressed on top of the right-hand work lever (joystick). The breaker / boost / shear selector switch must be in the "O"...
  • Page 150 Work Levers (Joysticks) (ISO Style) WARNING Check surrounding area before swinging. When operating a lever while in auto idle, do it carefully, because the engine speed will increase rapidly. NOTE: When starting work, move work levers (joysticks) FG000381 slowly and check movement of swing and front Figure 45 attachment.
  • Page 151 Change Machine Control Pattern by Select Valve (If Equipped) WARNING Check surrounding area before swinging. When operating a lever while in auto idle, do it carefully, because the engine speed will increase rapidly. FG000381 Figure 49 NOTE: When starting work, move work levers (joysticks) <ISO PATTERN>...
  • Page 152 Work Levers (Joysticks) (BHL Style) Left-hand Work Lever (Joystick) (Figure 49 and Figure 51) Boom down Boom up Left swing Right swing NOTE: The swing brake is spring applied and hydraulically released. It is always engaged when the work lever (joystick) is in "NEUTRAL" or the engine is shut down.

  • Page 153: 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 154 Do not use machine travel or swing when the bucket is in the ground to provide additional breakout force. See Figure FG000134 Figure 57 Do not use weight of machine to provide additional breakout force. See Figure 58. When working on soft or muddy ground, make sure that machine is not sinking.
  • Page 155 11. Make sure there is adequate clearance from overhead electrical supply lines. See Figure 61. FG000171 Figure 61 12. If the excavation is in an underground location or in a building, make sure there is adequate overhead clearance and there is adequate ventilation. See Figure 62. FG000172 Figure 62 13.
  • Page 156 15. Do not operate travel lever quickly when traveling in high range. • Avoid sudden starts. • When traveling in one direction come to a complete stop before reversing directions. Do not rock excavator back and forth with levers. • Avoid sudden stops.
  • Page 157 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 and engine ECU damage. FG000179 Figure 66 When working in water, do not operate in water over center of...

  • Page 158: Parking Excavator

    PARKING EXCAVATOR WARNING Park excavator on firm, level ground. Avoid parking on slopes. If excavator must be parked on a slope, block tracks and place bucket teeth in ground. See Figure 68. FG000214 Figure 68 Park excavator on firm, level ground. Lower bucket to ground as shown in Figure 69.

  • Page 159: Towing Procedure

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

  • Page 160: 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 161 Hydraulic Breaker Operation NOTE: Hydraulic pressure and flow settings may need to be changed. Refer to the Maintenance Section of this manual for further information. Make sure to read and understand the breaker user's manual. Inspect all mechanical and hydraulic connections. Do not use the breaker as a hammer.
  • Page 162 Do not allow the breaker body to go into water if not equipped for underwater operation. The breaker seal can be damaged and allow rust, foreign material or water to enter the hydraulic system and cause damage. Only insert the breaker tool into water. See Figure 76. HAOB970L Figure 76 Do not any lifting or towing with a breaker.
  • Page 163 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 80 RIGHT-HAND WORK LEVER (JOYSTICK) Relief Valve Adjustment...
  • Page 164 Hydraulic Breaker Work 100% 500 Hours 100 Hours These service intervals only apply, when a genuine DOOSAN oil and filter are used. If any other brands are used, the guaranteed changed interval should be reduced in half. 105 116 FILTER...

  • Page 165: Adjusting The Pump Flow

    ADJUSTING THE PUMP FLOW NOTE: For further information, see “Flow Control” on page 2-41. On the instrument panel, press the flow control button , the flow control screen (Figure 83) will be displayed. Use "UP" ( ) or "DOWN" ( ) buttons to adjust flow rate.
  • Page 166 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 rocking pedal back and forth between positions (1 and 2, Figure 84). When pedal is in its center (at rest) position the valve is in "NEUTRAL" and hydraulic oil flow is stopped.
  • Page 167 Rotating Pedal Valve (Optional) Attachment Rotating by Using the Pedal Valve Pressing end (1, Figure 87) is used to turn clockwise. Pressing Figure used turn counterclockwise. NOTE: Before activating the pedal, be sure to check the function of the attachment. FG000405 Figure 87 Locking the Pedal...

  • Page 168: 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 169 Lifting Known Weight The load chart is the governing factor when lifting known weights. It is recommended that you feel your way into any lift as a precaution against tip-over. Whenever possible, lift and swing payloads between the front idler area. Pick and Carry The machine can pick and carry payloads without added labor.

  • Page 170: Operation Under Unusual Conditions

    OPERATION UNDER UNUSUAL CONDITIONS NOTE: “Maintenance Special Conditions” page 4-83 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 171 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 172 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 173 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 174 Operation OP001761 3-48...

  • Page 175: Inspection, Maintenance And Adjustment

    OP001762 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 176 Please make note of these numbers and their locations. These will be required whenever warranty or service work is requested. Keep this number on file, incase the machine is stolen. Figure 3 Doosan Infracore Co., Ltd. 489, Injung-ro, Dong-gu, Incheon, Korea FG027603 Figure 4...
  • Page 177 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 178: 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 179 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 180: Table Of Recommended Lubricants

    TABLE OF RECOMMENDED LUBRICANTS IMPORTANT It is highly recommend to use the DOOSAN Genuine Products, or products which meet the specification below. Using other products may damage the equipment. NOTE: Refer to the Maintenance Intervals Table for application points. Ambient Temperature...
  • Page 181 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. API: American Petroleum Institute.

  • Page 182: 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.) 400 liters Fuel Tank (105 U.S. gal.) 140 liters Tank Level (37 U.S. gal.) Hydraulic Oil 240 liters System (63 U.S.
  • Page 183 Inspection, Maintenance and Adjustment OP001762...
  • Page 184 Description of Lubrication and Service Chart 250h 500h 1000h 2000h FG014179 Figure 11 Inspection, Maintenance and Adjustment OP001762 4-10...
  • Page 185 F100: Every 10 Hours For First 100 Hours. W10: Every 10 Hours If Operating In Water. EG: Ethylene Glycol - Doosan Genuine Antifreeze Solution (Drain and replace using this interval.) See “Engine Cooling System” on page 4-71, for further explanation.

  • Page 186: Maintenance Intervals

    MAINTENANCE INTERVALS SERVICE ITEM PAGE 10 Hour / Daily Service Grease Boom, Arm and Front Attachment Pins (for first 100 hours) 4-14 Check Engine Oil Level 4-14 Check Level of Hydraulic Oil Tank 4-15 Check for Leaks in Hydraulic System 4-16 Check Fuel Level 4-16...

  • Page 187: Service Item

    Major Parts - Periodic Replacement 4-53 12,000 HOUR / SIX YEAR SERVICE Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) 4-54 ** These checks need to be completed by an authorized DOOSAN dealer. Inspection, Maintenance and Adjustment OP001762 4-13...

  • Page 188: Hour / Daily Service

    10 HOUR / DAILY SERVICE Grease Boom, Arm and Front Attachment Pins (for first 100 hours) WARNING Do not remove grease fitting until pressure is entirely bleed off by loosening grease fitting slowly to avoid fatal wound. Let anybody never be in the blowing direction. FG000500 Be careful to any kinds of works for nipples and hydraulic Figure 12...

  • Page 189: Check Level Of Hydraulic Oil Tank

    Check Level of Hydraulic Oil Tank WARNING The hydraulic oil will be hot after normal machine operation. Allow the system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Turn the breather cap slowly to allow the pressurized air to vent.

  • Page 190: Check For Leaks In Hydraulic System

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

  • Page 191: Check For Leaks In Fuel System

    Securely tighten cap after fueling. NOTE: If breather holes (3, Figure 21) in cap are clogged, a vacuum may form in the tank preventing proper fuel flow to engine. Keep holes in fuel cap clean. FG000317 Figure 21 Check for Leaks in Fuel System Perform an inspection of the engine compartment to verify that fuel system is not leaking.

  • Page 192: Check Oil Level Of Swing Reduction Device

    Check Oil Level of Swing Reduction Device WARNING The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before fully removing any motor case inspection port plug, etc., loosen the plug slightly to allow pressurized air to escape.

  • Page 193: Clean Dust Net In Front Of Oil Cooler And Intercooler

    Clean Dust Net in Front of Oil Cooler and Intercooler IMPORTANT If running excavator in dusty area, check dust net everyday and clean it if dirty. WARNING FG013202 If using compressed air or water to clean the dust net, make Figure 27 sure that proper eye protection is worn.

  • Page 194: Check Level Of Window Washer Liquid

    Do not allow the replaceable bucket teeth to wear down to the point that bucket adapter is exposed. See Figure 30. NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers' buckets, refer to their specific instructions.

  • Page 195: 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 FG001386 on air intake system.

  • Page 196: Check The Operation Of All Exterior Lights, Horn And Control Console Indicator And Monitor

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

  • Page 197: Hour / Weekly Service

    50 HOUR / WEEKLY SERVICE Perform All Daily Service Checks Grease 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 198: 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) FG001438 Figure 35 Bucket cylinder rod pin (1 point) FG001439 Figure 36 Grease Swing Bearing Park machine on firm, level ground. Lower the front attachment to the ground and shut down engine.

  • Page 199: Drain Water And Sediment From Fuel Tank

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

  • Page 200: Hour / Monthly Service

    250 HOUR / MONTHLY SERVICE Perform All Daily and 50 Hour Service Checks Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours) NOTE: Change swing reduction device oil after first 250 hours on a new machine and every 2,000 hours thereafter (See page 4-47).

  • Page 201: Grease Arm And Front Attachment Pins

    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 202 Boom cylinder head pin (2 points) FG001389 Figure 40 Boom foot pin (2 points) Boom cylinder rod pin (2 points) Arm cylinder head pin (1 point) FG001390 Figure 41 Boom arm joint pin (2 points) Arm cylinder rod pin (1 point) Bucket cylinder head pin (1 point) FG001391 Figure 42...

  • Page 203: Check Engine Fan Belt Tension

    Check Engine Fan Belt Tension 10mm/10kg IMPORTANT COMPRESSOR A loose fan belt can cause engine overheating, poor ALTERNATOR charging, and/or premature belt wear. A belt that is too tight can cause damage to the water pump, alternator bearing or belt. CRANKSHAFT FG000353 Inspect every 250 hours.

  • Page 204: Check Oil Level In Travel Reduction Device (One On Each Side Of Unit)

    When replacing belts and pulleys, pulley alignment must be checked with belts tensioned and brackets securely clamped. A misalignment that can be detected by the eye is detrimental to belt performance. Do not force the belts into the pulley grooves by prying with a screwdriver or pry bar.

  • Page 205: 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. Park machine on firm, level ground. Lower the front attachment to the ground and shut down engine. Lift the hydraulic oil tank breather cap to release pressure.
  • Page 206 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear Check Fluid Levels in Batteries and Battery Charge Levels Inspect for Any Loose or Missing Nuts and Bolts Inspect Fuel System Hose Clamps Inspection, Maintenance and Adjustment OP001762 4-32...

  • Page 207: Hour / 3 Month Service

    500 HOUR / 3 MONTH SERVICE Perform All Daily, 50 and 250 Hour Service Checks Grease Swing Gear and Pinion WARNING Greasing swing gear and pinion must be serviced by only one person. Remove inspection cover and inspect the condition of the grease.
  • Page 208 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 209 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 unit is being operated in a dusty environment, the cleaning and replacement should be performed more frequently.
  • Page 210 Remove filter (Figure 54) 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 54 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 211 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, FG013205 mask and safety shoes during the cleaning precess. Make Figure 56 sure that all extra personnel are clear of the work area.
  • Page 212 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 58) on instrument panel comes "ON" the air cleaner must be serviced.
  • Page 213 Check outer filter by shinning a light through it. If small holes or thinner parts are found on the element after cleaning it, replace the filter. Clean the inside of the air cleaner body and the inside of the air cleaner cover. Do not use compressed air. Properly install the air filter and cover.
  • Page 214 Change Fuel Filter WARNING Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. Locate fuel filter inside engine compartment. Position a small container under fuel filter. FG000773 Figure 64 Unscrew fuel filter from head assembly. Discard fuel filter. NOTE: Dispose of drained fluids according to local regulations.

  • Page 215: Hour / 6 Month Service

    1,000 HOUR / 6 MONTH SERVICE Perform All Daily, 50, 250 and 500 Hour Service Checks Grease Swing Reduction Device Park machine on firm, level ground. Lower the front attachment to the ground and shut down engine. Remove air vent plug (1, Figure 68) from swing reduction device.
  • Page 216 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 70) on instrument panel comes "ON" the return filter must be serviced.
  • Page 217 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 73) on instrument panel comes "ON" the pilot filter must be serviced.
  • Page 218 Change Oil in Travel Reduction Device (One on Each Side of Unit) WARNING The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before fully removing any motor case, inspection port plug, etc., loosen the plug slightly to allow pressurized air to FG001392 escape.
  • Page 219 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 220 High No bubbles are seen. HFC-134a 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 221: 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 222 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 85 2,000 hours of service. NOTE: Replace inner element whenever a new outer element is installed.
  • Page 223 Mixed solution may degrade the capabilities of the system. It is recommended to use the standard product from DOOSAN. In the bitterly cold area or weather, the customer should frequently check the performance of the coolant for appropriateness for the weather, and then determine change cycle of the coolant.
  • Page 224 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 225 Park machine on firm, level ground. Swing upper structure perpendicular (90°) to tracks. Lower boom and position bucket on ground as shown in Figure 92. Set safety lever on "LOCK" position. Shut down engine. Release pressurized air from hydraulic tank by lifting breather cap (1, Figure 95).
  • Page 226 13. Check level of hydraulic oil tank. (See page 4-15) ARO1720L Figure 95 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 227: 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 228: Hour / 6 Year Service

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

  • Page 229: 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 230: Bolt And Nut Inspection

    250 hours thereafter. If any are loose or are missing tighten them or install new hardware. Always use a calibrated torque wrench. IMPORTANT Always clean fasteners before tightening. If counterweight is loose, contact a DOOSAN distributor or sales agent. BOLT BOLT TORQUE POINT TO BE INSPECTED DIA.
  • Page 231 Joint bolt with engine mounting bracket and engine 1) Pump side • Tool: 24 mm ( • Torque: 27 kg•m (264 N•m, 195 ft lb) FG001416 Figure 96 2) Fan side • Tool: 17 mm ( • Torque: 5 kg•m (49 N•m, 36 ft lb) FG001417 Figure 97 Joint bolt and nut between engine mounting bracket and...

  • Page 232: Radiator Mounting Bolt

    Radiator mounting bolt • Tool: 24 mm ( • Torque: 27 kg•m (265 N•m, 195 ft lb) FG001420 Figure 100 Tightening bolt for hydraulic oil tank • Tool: 24 mm ( • Torque: 27 kg•m (265 N•m, 195 ft lb) FG006450 Figure 101 Tightening bolt for fuel tank...

  • Page 233: Tightening Bolt For Control Valve

    Tightening bolt for control valve • Tool: 24 mm ( • Torque: 27 kg•m (265 N•m, 195 ft lb) FG001425 Figure 104 Tightening bolt for swing reduction device • Tool: 30 mm ( • Torque: 55 kg•m (539 •Nm, 398 ft lb) FG001426 Figure 105 Tightening bolt for swing motor...

  • Page 234: Joint Bolt With Cabin Mounting Rubber And Frame

    11. Joint bolt with cabin mounting rubber and frame • Tool: 17 mm ( • Torque: 6.5 kg•m (64 N•m, 47 ft lb) FG000454 Figure 108 Joint bolt with cabin mounting rubber and cabin • Tool: 24 mm ( • Torque: 21 kg•m (206 N•m, 152 ft lb) FG000455 Figure 109...

  • Page 235: Tightening Bolt For Travel Device

    13. Tightening bolt for travel device • Tool: 24 mm ( • Torque: 30 kg•m (294 N•m, 217 ft lb) FG001431 Figure 112 Tightening bolt for sprocket • Tool: 22 mm ( • Torque: 30 kg•m (294 N•m, 217 ft lb) FG001432 Figure 113 14.

  • Page 236: Tightening Bolt For Track Guard

    16. Tightening bolt for track guard • Tool: 24 mm ( • Torque: 27 kg•m (265 N•m, 195 ft lb) FG000462 Figure 116 17. Bolt for track shoes • Tool: 27 mm ( • Torque: 78 kg•m (765 N•m, 564 ft lb) FG000463 Figure 117 18.

  • Page 237: Breaker Filter (Optional)

    19. Fixing breaker filter (Optional) • Tool: 30 mm ( • Torque: 27 kg•m (265 N•m, 195 ft lb) FG005867 Figure 119 20. Grease valve for track adjuster • Tool: 27 mm ( • Torque: 14 kg•m (137 N•m, 101 ft lb) FG000163 Figure 120 Inspection, Maintenance and Adjustment...

  • Page 238: 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 239 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. FG005886 Figure 123 Roll old O-ring (1, Figure 124) onto boss (2) around bucket pin (3).
  • Page 240 Roll new O-ring (1, Figure 126) into O-ring groove. ARO1392L Figure 126 Inspection, Maintenance and Adjustment OP001762 4-66...

  • Page 241: 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 242 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 243 Fuse Boxes There are two fuse boxes (Figure 130) on the left side of the heater box. The fuses prevent electrical devices from overloading or shorting. A decal attached inside the fuse box's cover indicates the function and amperage of each fuse. Spare fuses are mounted on the inside of fuse box's cover.
  • Page 244 Fuse Identification Fuse Box (1) Fuse Box (2) FG000542 Figure 131 Fuse Box One Fuse Box Two Name Capacity Name Capacity Warning Light (Optional) Horn 2-pump (Optional) Quick Clamp (Optional) Cigar Lighter Travel Alarm (Optional) 12V Power Auxiliary Mode Engine Throttle Control, Wiper, Washer After Heat Relay Lower Wiper (Optional)

  • Page 245: 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 246 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 247 Antifreeze Concentration Tables Ethylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons) (2,000 Hour / Yearly) Ambient Temperature Cooling Water Antifreeze -10°C (14°F) -15°C (5°F) -20°C (-4°F) -25°C (-13°F) -30°C (-22°F) -40°C (-40°F) Propylene Glycol - Doosan Genuine Antifreeze Solution (for all seasons)

  • Page 248: Fuel Transfer Pump (Optional)

    FUEL TRANSFER PUMP (OPTIONAL) WARNING Do not dry operate fuel pump for more than fifteen seconds. • Cooling and lubrication of pump is achieved by fuel passing through pump. If pump is dry operated, heat generated by moving parts will cause damage to pump rotors, vanes and seals.
  • Page 249 The transfer pump is used to transfer fuel from a refueling source to the fuel tank. A check valve is installed in the inlet hose to prevent fuel from flowing back from fuel tank to source. A strainer is installed in inlet hose to prevent any foreign material from being introduced into transfer pump or fuel tank.

  • Page 250: 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 251: Track Tension

    TRACK TENSION WARNING Safely measuring track tension requires two people. One person must be in the operator's seat, running the controls to keep one side frame in the air, while the other person makes dimensional checks. Take all necessary precautions to make sure the machine won't move or shift position during service.
  • Page 252 The increased clearance recommended for muddy, sandy or snowy ground conditions is between 340 - 370 mm (13.39 - 14.57 in). WARNING track adjusting mechanism under very high-pressure. NEVER release pressure too suddenly. The grease cylinder valve should never be backed off more than 1 complete turn from the fully snugged down position.

  • Page 253: 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. Shot down engine, remove vent plug (Figure 138) to see if any oil is present.
  • Page 254 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. FG001411 Figure 139 Disconnect drain hose and fill swing motor case with hydraulic oil.

  • Page 255: Long Term Storage

    LONG TERM STORAGE When a machine is taken out of service and stored for a time exceeding 30 days, steps must be taken to protect the machine. Leaving equipment outdoors exposed to the elements will shorten its life. An enclosure will protect the machine from rapid temperature changes and lessen the amount of condensation that forms in hydraulic components, engine, fuel tank, etc.
  • Page 256 During Storage • Once a month, start the engine and follow the "Hydraulic Oil Warm-up" procedures listed in this manual. NOTE: Remove all seals from the machine (i.e. crankcase and hydraulic breathers, engine air intake, fuel tank vent lines, etc.). Operate hydraulic functions for traveling, swing and digging two or three times for lubrication after "Hydraulic Oil Warm-up."...

  • Page 257: Maintenance In Special Conditions

    MAINTENANCE IN SPECIAL CONDITIONS NOTE: See “Operation Under Unusual Conditions” on page 3-44 for other recommendations. Conditions Maintenance Required Operating in mud, water or rain. Perform a walk around inspection to check for any loose fittings, obvious damage to the machine or any fluid leakage. After completing operations, clean mud, rocks or debris from the machine.
  • Page 258 Inspection, Maintenance and Adjustment OP001762 4-84...

  • Page 259: Transportation

    Warning for Counterweight and Front Attachment Removal DANGER DOOSAN warns any user, that 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 260 WARNING When transporting the machine, know the width, height, length and weight. Loading or unloading the machine can be a dangerous operation. Make sure to run the engine at the lowest speed setting, and travel at the slowest speed possible. Make sure that ramp being used can handle the weight of the machine.
  • Page 261 Set the travel speed selector switch to "O" (OFF) position. See Figure 3. FG000023 Figure 3 Turn "OFF" auto idle selector button (1, Figure 4). The indicator light (2) will not be lit. Set engine speed to "LOW IDLE." POWER AUTO FG014212 Figure 4...
  • Page 262 Extend bucket and arm cylinders to maximum length and then lower the boom slowly. FG000327 Figure 7 10. Set safety lever on "LOCK" position. Unlock lock FG001091 Figure 8 11. Shut down engine by turning key to "O" (OFF) position (Figure 9).

  • Page 263: Lifting With Sling

    FG014870 Figure 11 LIFTING WITH SLING WARNING Improper lifting can allow load to shift and cause injury or damage. Refer to “Specification” on page 7-1 of this manual for information on weight and dimensions. Use properly rated cables and slings for lifting. Position machine for a level lift.
  • Page 264 Transportation OP001763...

  • Page 265: Troubleshooting

    If cause for the malfunction cannot be determined, contact your DOOSAN distributor. Never perform an adjustment of or disassembly of, hydraulic components, electrical and electronic components, without first consulting a DOOSAN distributor.

  • Page 266: Engine

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

  • Page 267: Hydraulic System

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

  • Page 268: 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 269: Specification

    OP001764 Specification STANDARD SPECIFICATION SPECIFICATION COMPONENT METRIC ENGLISH CECE 0.81 m 1.06 yd Bucket Capacity PCSA 0.92 m 1.20 yd Equipment Weight 21.5 metric tons 23.7 tons Model DB58TIS Type Water Cooled - 6 Cylinders Engine Rated Output 150 ps @1,900 rpm 148 hp @1,900 rpm Maximum Torque 61.5 kg•m @ 1,400 rpm...

  • Page 270: Overall Dimensions

    OVERALL DIMENSIONS DX220A FG013209 Figure 1 5.2 m (17' 1") BOOM 5.7 M (18' 8") BOOM DIMENSION 2.0 m (6' 6") ARM 2.4 m (7' 10") ARM 2.4 m (7' 10") ARM 2.9 m (9' 6") ARM 9,080 mm (29' 9") 8,990 mm (29' 6")
  • Page 271 DX225LCA FG013209 Figure 1 5.2 m (17' 1") BOOM 5.7 m (18' 8") BOOM DIMENSION 2.0 m (6' 6") ARM 2.4 m (7' 10") ARM2.4 m (7' 10") ARM 2.9 m (9' 6") ARM 3.5 m (11' 6") ARM 9,080 mm (29' 9") 8,990 mm (29' 6") 9,500 mm (31' 2") 9,485 mm (31' 1") 9,500 mm (31' 2") 2,750 mm (9' 0") 6,330 mm (22' 9") 6,240 mm (20' 6") 6,750 mm (22' 8") 6,735 mm (22' 1") 6,750 mm (22' 2") 3,650 mm (11' 12")

  • Page 272: Working Range

    WORKING RANGE FG005888 Figure 2 5.2 m (17' 1") BOOM 5.7 m (18' 8") BOOM DIMENSION 2.0 m (6' 6") ARM 2.4 m (7' 10") ARM2.4 m (7' 10") ARM 2.9 m (9' 6") ARM 3.5 m (11' 6") ARM 8,580 mm (28' 2") 8,950 mm (29' 4") 9,480 mm (31' 1") 9,900 mm (32' 6") 10,340 mm (33'11") 5,350 mm (17' 7") 5,750 mm (18' 10") 6,110 mm (20' 1") 6,620 mm (21' 7") 7,220 mm (23' 8") 6,080 mm (19' 11") 9,060 mm (8' 7")

  • Page 273: Approximate Weight Of Workload Materials

    APPROXIMATE WEIGHT OF WORKLOAD MATERIALS IMPORTANT Weights are approximations of estimated average volume and mass. Exposure to rain, snow or ground water; settling or compaction due to overhead weight and chemical or industrial processing or changes due to thermal or chemical transformations could all increase value of weights listed in table.
  • Page 274 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS 961 kg/m Gypsum, calcined, (heated, powder) --------------------- --------------------- (1,620 lb/yd...

  • Page 275: Index

    Index 2-62 Numerics Cabin Storage Compartments 2-12 4-41 Cabin Work Light Switch 1,000 Hour / 6 Month Service 2-58 4-14 Ceiling Cover 10 Hour / Daily Service 2-23 Charge Warning Light 4-54 12,000 Hour / 6 Year Service 4-47 Check and Confirmation After Stopping Engine 2,000 Hour / Yearly Service 4-26 250 Hour / Monthly Service...
  • Page 276 2-21 4-76 Coolant Temperature Gauge Handling of Accumulator 2-23 2-63, 2-64 Coolant Temperature Warning Light Hanger 2-65 4-52 Cover Head Bolt Torques 2-10 2-12 Emergency Stop Cable Headlight Switch 4-29 2-45 Fan Belt Heater and Air Conditioner 4-52 2-50 Head Bolt Torques Additional Operating Instruction 4-25, 4-34 2-13, 2-46...
  • Page 277 4-16 4-48 Leaks in the Hydraulic System Outer Air Cleaner Element 4-38 Levers Outer Element of Air Cleaner 2-55 Adjusting Reclining Overall Dimensions 2-54 2-44 Adjusting the Seat Forward Overload Alarm Selection 2-54 Adjusting the Seat's Angle 2-55 Angle Adjustment of Armrest 2-18 Safety Lever Panels...
  • Page 278 2-54 2-17 Adjusting the Seat's Angle Booster Button 2-55 2-12 Adjustment of Lumbar Support Cabin Work Light Switch 2-57 2-15 Air Suspension Seat Cigar Lighter 2-55 2-14 Angle Adjustment of Armrest Constant Speed Button 2-55 2-33 Headrest Display Selector Button 2-57 2-33 Left ad Right Control Stand Location...
  • Page 279 Windows 2-64 4-79 Door Window Holder Venting and Priming Hydraulic System 2-59 4-80 Front General Venting 2-60 4-79 Front Bottom Hydraulic Cylinders 2-59 4-79 Front Upper Main System Pump 2-59 4-80 Opening Swing Motor 2-63 Sun Visor 2-13 Wiper Switch (Lower) 2-14 Wiper Switch Panel 2-13...

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