DX35Z

Operation and Maintenance Manual

K1025196E
Serial Number 5001 and Up
September 2006

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

K1025196E Operation and Maintenance Manual Copyright Doosan 2006

 Table of Contents
Safety..........................................................................................1-1
To the Operator of a DOOSAN Daewoo 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 ................................................................... 1-24
Machine Operation.......................................................................... 1-28
Maintenance .................................................................................... 1-36
Battery.............................................................................................. 1-45
Towing ............................................................................................. 1-47
Shipping and Transportation .......................................................... 1-48
Excavator Rated Lift Capacity Tables........................................... 1-49

Operating Controls ...................................................................2-1

Component Locations ....................................................................... 2-2
Operator's Area................................................................................. 2-4
Operational Controls and Panels..................................................... 2-6
instrument Panel ............................................................................. 2-13
Stereo (Optional)............................................................................. 2-18
Fuse boxes...................................................................................... 2-19
Miscellaneous Electrical Devices ................................................... 2-20
Heating and Air Conditioning System (Optional) ......................... 2-21
Seat Adjustment.............................................................................. 2-24
Seat Belt.......................................................................................... 2-24
Front Windows ................................................................................ 2-26
Door Side Latch.............................................................................. 2-28

K1025196E Table of Contents

I
 Cabin Storage Compartments........................................................ 2-28
Hanger ............................................................................................. 2-29
Cup Holder ...................................................................................... 2-29
Emergency Glass Breaking Tool ................................................... 2-29

Operation....................................................................................3-1
To Handle a New Excavator ........................................................... 3-1
Starting and Stopping the Engine ................................................... 3-2
Safety Lever .................................................................................... 3-13
Travel ............................................................................................... 3-14
Operating Instructions ..................................................................... 3-19
Operating Precautions .................................................................... 3-23
Parking Excavator ........................................................................... 3-27
Towing Procedure ........................................................................... 3-28
Hydraulic Breaker............................................................................ 3-29
Operating Techniques..................................................................... 3-36
Operation Under Unusual Conditions............................................ 3-38

Inspection, Maintenance and Adjustment ............................4-1

Preventive Maintenance.................................................................... 4-1
Preliminary Work Machine Setup for Maintenance........................ 4-3
Table of Recommended Lubricants................................................. 4-5
Fluid Capacities................................................................................. 4-7
Lubrication and Service Chart ......................................................... 4-7
Maintenance Intervals ..................................................................... 4-10
10 Hour / Daily Service ................................................................. 4-12
50 Hour / Weekly Service ............................................................. 4-20
250 Hour / Monthly Service .......................................................... 4-23
500 Hour / 3 Month Service ......................................................... 4-29
1,000 Hour / 6 Month Service ...................................................... 4-31
2,000 Hour / Yearly Service.......................................................... 4-33
4,000 Hour / Biennial Service ....................................................... 4-37
12,000 Hour / Six Year Service.................................................... 4-38

K1025196E Table of Contents

II
 Air-Conditioning System.................................................................. 4-39
Bolt and Nut Inspection ................................................................. 4-40
Bucket .............................................................................................. 4-41
Electrical System............................................................................. 4-47
Engine Cooling System .................................................................. 4-50
Handling of Accumulator ................................................................ 4-54
Long Term Storage ........................................................................ 4-55
Maintenance in Special Conditions ............................................... 4-56
Track Tension ................................................................................. 4-57
Venting and Priming Hydraulic System ........................................ 4-59

Transportation ...........................................................................5-1
Loading and Unloading .................................................................... 5-1
Lifting With Sling............................................................................... 5-4

Troubleshooting ........................................................................6-1
Control Valve..................................................................................... 6-1
Relief Valve ....................................................................................... 6-2
Center Joint....................................................................................... 6-2
Control Lever..................................................................................... 6-3
Attachments ....................................................................................... 6-3
Hydraulic Motor ................................................................................. 6-4
Hydraulic Cylinder ............................................................................. 6-4
Hydraulic Pump................................................................................. 6-5
Swing System ................................................................................... 6-5
Travel ................................................................................................. 6-6

Specification ..............................................................................7-1
Standard Specification ...................................................................... 7-1
Overall Dimensions ........................................................................... 7-2
Working Range ................................................................................. 7-4
Approximate Weight of Workload Materials.................................... 7-5

K1025196E Table of Contents

III
 Index ...........................................................................................8-1

K1025196E Table of Contents

IV
 OP000468

1Safety

TO THE OPERATOR OF A
DOOSAN DAEWOO
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.

Please respect the importance of taking responsibility for

your own safety, and that of other people who may be
affected by your actions.
The safety information on the following pages is organized
into the following sections:
1. “Location of Safety Labels” on page 1-5
2. “Summary of Safety Precautions for Lifting in Digging
Mode” on page 1-13
3. “Unauthorized Modifications” on page 1-14
4. “General Hazard Information” on page 1-14
5. “Before Starting Engine” on page 1-24
6. “Machine Operation” on page 1-28
7. “Maintenance” on page 1-36
8. “Battery” on page 1-44
9. “Towing” on page 1-46
10. “Shipping and Transportation” on page 1-47
11. “Excavator Rated Lift Capacity Tables” on page 1-48

Safety OP000468
1-1
 WARNING!
Improper operation and maintenance of this machine
can be hazardous and could result in serious injury or
death.
Operator and maintenance personnel should read this
manual thoroughly before beginning operation or
maintenance.
Keep this manual in the storage compartment to the
rear of the operator's seat, and have all personnel
involved in working on the machine read the manual
periodically.
Some actions involved in operation and maintenance of
the machine can cause a serious accident, if they are
not done in a manner described in this manual.
The procedures and precautions given in this manual
apply only to intended uses of the machine.
If you use your machine for any unintended uses that
are not specifically prohibited, you must be sure that it
is safe for any others. In no event should you or others
engage in prohibited uses or actions as described in
this manual.
DOOSAN delivers machines that comply with all
applicable regulations and standards of the country to
which it has been sent. If this machine has been
purchased in another country or purchased from
someone in another country, it may lack certain safety
devices and specifications that are necessary for use in
your country. If there is any question about whether
your product complies with the applicable standards and
regulations of your country, consult DOOSAN or your
DOOSAN distributor before operating the machine.

Safety OP000468
1-2
 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 precautions and follow
recommended procedures.

Learn the Signal Words Used with the

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," no matter which signal word appears next to
the "Exclamation Point" symbol.

CAUTION!
This word is used on safety messages and safety labels
and indicates potential threat of a hazardous situation
that, if not avoided, could result in minor or moderate
injury. It may also be used to alert against a generally
unsafe practice.

WARNING!
This word is used on safety messages and safety labels
and indicates potential threat of a hazardous situation
that, if not avoided, could result in serious injury or
death. It may also be used to alert against highly unsafe
practice.

DANGER!
This word is used on safety messages and safety labels
and indicates an imminent hazard of a situation that, if
not avoided, is very likely to cause death or extremely
serious injury. It may also be used to alert against
equipment that may detonate or explode if handled or
treated carelessly.

Safety OP000468
1-3
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 actions not specifically recommended or
allowed in this manual are used, you must be sure that you
and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the
safety of any procedures, contact a DOOSAN distributor.

Safety OP000468
1-4
LOCATION OF SAFETY
LABELS

5 6
2 1 5 2

6 1 3

11
10
CANOPY TYPE
9 8

12

7 4

FG007474
Figure 1

There are several specific warning signs on this machine.

The exact location of hazards and the description of the
hazards are reviewed in this section.
Please become familiarized with all warning signs.
Make sure that all the warning signs are legible. Clean the
warning signs or replace the warning signs if you cannot
read the words. Replace the illustrations if the illustrations
are not visible. When you clean the warning signs, use a
cloth, water and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety signs. Solvents,
gasoline, or other harsh chemicals could loosen the
adhesive that secures the warning sign. Loose adhesive will
allow the warning sign to fall off.

Safety OP000468
1-5
Replace any safety sign that is damaged, or missing. If a
safety sign is attached to a part that is replaced, install a
safety sign on the replacement part.

Safety OP000468
1-6
1. Warnings for Operation, Inspection
and Maintenance (190-00688,
190-00092)

AVOID DEATH OR SERIOUS INJURY. - READ AND UNDERSTAND

OPERATION MANUAL AND SAFETY LABELS prior to operating
this machine.

Never get in under the machine while it is being jacked up

with boom and ar m.
Sound the hor n to aler t the people nearby before operating,
and make sure that all persons are clear of area.
Controls may be changed for attachments or operator 190-00092
preference. Tr y control patter n before operating.

190-00688
ARO1080L

2. Warnings for High Voltage

(190-00689, 190-00096)

DANGER
SERIOUS INJURY OR DEATH BY
ELECTROCTION can occur if
machine or attachments are
not a safe distance from electrical
power lines.
Line voltage Safe Distance
6.6 kv At least 3m(10ft)
66.6 kv At least 5m(16ft) 190-00096
275.0 kv At least 10m(33ft)
190-00689
ARO1090L

Safety OP000468
1-7
3. Warnings When Opening a Front
Window (2190-3388, 190-00093)

2190-3388
190-00093
FG000665

4. Warnings for a High-pressure

Cylinder (190-00122)

190-00122

ARO1110L

Safety OP000468
1-8
5. Warnings When Adjusting Track
Tension (2190-3386A, 190-00521)

2190-3386A
190-00521
ARO1120L

6. Warnings for Leaving Operator's

Seat (190-00693, 190-00094)

190-00693

190-00094
ARO1140L

Safety OP000468
1-9
7. Warnings for Batteries Maintenance
(2190-2533A, 190-00100)

2190-2533A 190-00100
ARO1150L

8. Warnings for High Temperature

Hydraulic Oil (190-00691, 190-00097)

190-00097

190-00691
ARO1160L

Safety OP000468
1-10
9. Warnings for Hot Coolant (190-00692,
190-00097)

190-00097

ARO1170L

10. Warnings for Rotating Parts

(190-00694, 190-00095, 190-00557)

190-00095

190-00557

ARO1190L

Safety OP000468
1-11
11. Warning Tag - Used When Inspection
and Maintenance (190-00695,
190-00098)

WARNING
DO NOT OPERATE
when performing inspection
or maintenance

190-00695
190-00098

ARO1200L

12. Keep Out of the Swing Area

(2190-3380A, 190-00163)

2190-3380A

190-00163

FG008064

Safety OP000468
1-12
SUMMARY OF SAFETY
PRECAUTIONS FOR LIFTING IN
DIGGING MODE

DANGER!
Unsafe use of the excavator while making rated lifts
could cause serious, potentially fatal injuries or
extensive damage to the machine or nearby property.
Do not let anyone operate the machine unless they've
been properly trained and understand the information in
the Operation and Maintenance Manual.

To lift safely while in Digging Mode, the following items must

be evaluated by the operator and the work site crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Tag lines on opposite sides of the load can be very helpful
in keeping a suspended load secure, if they are anchored
safely to control points on the ground.

WARNING!
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind
gusts are more than 48.3 km/h (30 MPH). Be prepared
for any type of wind gust when working with loads that
have a large surface area.

Always engage the "Digging Mode" control on the Instrument

Panel before using the excavator for lifting work.

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

Safety OP000468
1-13
UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written
approval from DOOSAN can create a safety hazard, for
which the machine owner will be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine DOOSAN part. For example, not
taking the time to replace fasteners, bolts or nuts with the
correct replacement parts could lead to a condition where
the safety of critical assemblies are dangerously compromised.

GENERAL HAZARD
INFORMATION

Safety Rules
Only trained and authorized personnel can operate and
maintain the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if
you are taking medication that makes you feel sleepy, if you
have been drinking, or if you are suffering from emotional
problems. These problems will interfere with your sense of
judgment in emergencies and may cause accidents.
When working with another operator or with a person on
work site traffic duty, be sure that all personnel know the
nature of the work and understand all hand signals that are
to be used.
Always observe strictly any other rules related to safety.

Safety Features
Be sure that all guards and covers are installed in their
proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety
features such as safety lock lever and the seat belt, and
use them properly.
Never remove any safety features. Always keep them in
good operating condition.
Failure to use safety features according to the instructions in
the Operation and Maintenance Manual could result in
serious bodily injury.

Safety OP000468
1-14
Inside Operator's Cabin
When entering the operator's cabin, always remove all mud
and oil from the soles of your shoes. If you operate the
travel pedal with mud or oil stuck to your shoes, your foot
may slip and this may cause a serious accident.
After using the ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to close
the ashtray. If the ashtray is left open, there is danger of
fire.
Do not stick suction pads to the window glass. Suction pads
act as a lens and may cause fire.
Do not leave lighters laying around the operator's cabin. If
the temperature inside the operator's cabin becomes high,
there is danger that the lighter may explode.
Do not use cellular telephones inside the operator's cabin
when driving or operating the machine. There is
danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cabin.
To ensure safety, do not use the radio or music
headphones when operating the machine. There is danger
that this may lead to a serious accident.
When operating the machine, do not put your hands or
head out of the window.
When standing up from the operator's seat, always place
safety lock lever securely in the "LOCK" position. If you
accidentally touch the work equipment levers when they are
not locked, the machine may suddenly move and cause
serious injury or damage.
When leaving the machine, lower the work equipment
completely to the ground, set safety lock lever to the
"LOCK" position and shut down engine. Use the key to lock
all the equipment. Always remove the key and take it with
you.

Clothing and Personal Protective Items

Secure long hair, and avoid loose clothing and jewelry.
These items have the tendency to catch on controls or
protrude into parts and cause serious injury or death.
Do not wear oily clothes. They are highly flammable.
Full eye protection, a hard hat, safety shoes and gloves
may be required at the work site.
While working on the machine, never use inadequate tools.
They could break or slip, causing injury, or they may not HAOA020L
adequately perform intended functions. Figure 2

Safety OP000468
1-15
Breathing Masks, Ear Protection May Be
Required
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution
may not be visible, but these hazards can cause disabling
or permanent injuries.
NOTE: The equivalent continuous A-weighted sound
pressure level at the workstation for this machine is
76 dB(A).
Measurement is obtained on a dynamic machine
following the procedures and cabin conditions as
described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the
machinery for this machine is 94 dB(A).
Measurement is obtained on a dynamic machine with
the procedures as described in 2000/14/EC.

Vibration Level Information

Hands/Arms: The weighted root mean square acceleration to
which the hands/arms are subjected, is less than 2.5 m/s2.
Whole body: The weighted root mean square acceleration to
which the whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine,
using measuring procedures as described in the following
standard: ISO 2631/1. ISO 5349, and SAE J1166.

Safety OP000468
1-16
Recommendations for Limiting
Vibrations
1. Select the right machine, equipment and attachments
for a particular application.
2. 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.
• Inspect and maintain the suspension and
adjustment mechanisms of the seat regularly.
3. Check that the machine is properly maintained.
• Tire pressure, brakes, steering, linkages, etc.
4. Steer, brake, accelerate, shift gears, move the
attachments and load the attachments smoothly.
5. Adjust the machine speed and travel path to reduce
the vibration level.
• Slow down if it is necessary when traveling
through rough terrain.
• When driving machine, avoid obstacles and
excessive rough terrain.
6. 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.
7. Travel over longer distance (e.g. on public roads) at
adjusted (medium) speed.
• Always adjust the speed to prevent bouncing.

Safety OP000468
1-17
Mounting and Dismounting
Before getting on or off the machine, if there is any oil,
grease, or mud on the handrails, steps, or track shoes, wipe
it off immediately. Always keep these parts clean. Repair
any damage and tighten any loose bolts.
Never jump on or off the machine. In particular, never get
on or off a moving machine. These actions may lead to
serious injury.
When getting on or off the machine, always face the
machine, and maintain three-point contact (both feet and
one hand or one foot and both hands) with the handrails,
steps, and track shoes to ensure that you support yourself
securely.
Never hold any control levers when getting on or off the
machine.
Apply the door lock securely. If you grip the handrail inside
the door when moving on top of the track shoes, and the
door lock is not applied securely, the door may move and FG006339
cause you to fall. Figure 3
Use the points marked by arrows in the diagram when
getting on or off the machine.

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. The machine must be parked
with controls, lights and switches turned "OFF." The engine
must be "OFF" and any flames, glowing embers, auxiliary
heating units or spark causing equipment must be
extinguished, turned "OFF" and/or kept well clear of the
machine.
Static electricity can produce dangerous sparks at the fuel Figure 4
filling nozzle. In very cold, dry weather or other conditions
that could produce a static discharge, keep the tip of the
fuel nozzle in constant contact with the neck of the fuel
filling nozzle, to provide a ground.
Keep fuel and other fluid reservoir caps tight and do not
start the engine until caps have been secured.

Safety OP000468
1-18
Precautions When Handling Fluids at
High Temperature
Immediately after operations are stopped, the coolant,
engine oil, and hydraulic oil are at highest temperatures and
the radiator and hydraulic tank are still under pressure.
Attempting to remove the cap, drain the oil or coolant, or
replace the filters may lead to serious burns. Always wait for
the temperature to go down, and follow the specified
procedures when carrying out these operations.
HAOA050L
Figure 5

To prevent hot coolant from spurting out, shut down engine,

wait for the coolant to cool, then loosen the cap slowly to
relieve the pressure.
To prevent hot oil from spurting out, shut down engine, wait
for the oil to cool, then loosen the cap slowly to relieve the
pressure.

HAOA060L
Figure 6

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:
• Use a respirator that is approved for use in an
asbestos-laden atmosphere.
ARO1770L
• Never use compressed air for cleaning.
Figure 7
• Use water for cleaning to keep down the dust.
• Work on the machine or component with the wind
at your back whenever possible.
• Always observe any regulations related to the
work site and working environment.

Safety OP000468
1-19
Injury from Work Equipment
Do not enter or put your hand, arm or any other part of
your body between movable parts, such as between the
work equipment and cylinders, or between the machine and
work equipment.
If the control levers are operated, the clearance between the
machine and the work equipment will change and this may
lead to serious damage or personal injury.
If going between movable parts is necessary, always
HDO1010L
position and secure the work equipment so it cannot move.
Figure 8

Fire Extinguisher and First Aid Kit

As a precaution if any injury or fire should occur, always do
the following.
• Be sure that fire extinguishers have been provided
and read the labels to ensure that you know how
to use them. It is recommended that an
appropriately sized (2.27 kg [5 lb] or larger)
multipurpose "A/B/C" fire extinguisher be mounted
in the cabin. Check and service the fire
extinguisher at regular intervals and make sure HDO1009L
that all work site crew members are adequately Figure 9
trained in its use.
• Provide a first aid kit in the storage compartment
and keep another at the work site. Check the kit
periodically and make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance
service, hospital and fire department near your
telephone.
If the machine catches fire, it may lead to serious personal
injury or death. If a fire occurs during operation, escape
from the machine as follows:
• Turn the starter switch to the "O" (OFF) position
and shut down engine.
• If there is time, use the fire extinguisher to
extinguish as much of the fire as possible.
• Use the handrails and steps to escape from the
machine.
The above is the basic method for escaping from the
machine, but changing the method may be necessary
according to the conditions, so carry out practice drills at the
work site.

Safety OP000468
1-20
Protection from Falling or Flying Objects
On work sites where there is danger that falling objects or
flying objects may hit the operator's cabin select a guard to
match the operating conditions to protect the operator.
Working in mines, tunnels, deep pits or on loose or wet
surfaces could produce danger of falling rock or hazardous
flying objects. Additional protection for the operator's cabin
could be required in the form of a FOPS (Falling Object
Protective Structure) or window guards.
HAOA110L
Figure 10

Never attempt to alter or modify any type of protective

structure reinforcement system, by drilling holes, welding,
remounting or relocating fasteners. Any serious impact or
damage to the system requires a complete integrity
reevaluation. Reinstallation, recertification and/or replacement
of the system may be necessary.
Contact your DOOSAN distributor for available safety 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. HAOA100L
Figure 11
For breaker operation, install a front guard and apply a
laminated coating sheet to the front glass. Contact your
DOOSAN distributor for recommendations.
When carrying out demolition or cutting operation, install a
front guard and top guard, and apply a laminated coating
sheet to the front glass.
When working in mines or quarries where there is danger of
falling rock, install FOPS (Falling Objects Protective
Structure) and apply a laminated coating sheet to the front
glass.
If any glass on the machine is broken, replace it with new
glass immediately.

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
optional kits.

Safety OP000468
1-21
Accumulator
The pilot control system is equipped with an accumulator.
For a brief period of time after the engine has been shut
down, the accumulator will store a pressure charge that may
enable hydraulic controls to be activated. Activation of any
controls may enable the selected function to operate under
force of gravity.
When performing maintenance on the pilot control system,
the hydraulic pressure in the system must be released as
described in “Handling of Accumulator” on page 4-54.
The accumulator is charged with high-pressure nitrogen gas,
so it is extremely dangerous if it is handled in the wrong
way. Always observe the following precautions:
• Do not drill or make any holes in the accumulator
or expose it to any flames, fire or heat source.
• Do not weld on the accumulator, or try attaching
anything to it.
• When carrying out disassembly or maintenance of
the accumulator, or when disposing of the
accumulator, the charged gas must be properly
released. Contact your DOOSAN distributor.
• Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause
serious injuries.

Indoor Ventilation
Engine exhaust gases can cause fatal accidents, and
unconsciousness, loss of alertness, judgment and motor
control and serious injury.
Make sure there is adequate ventilation before starting the
engine in any enclosed area.
You should also be aware of open windows, doors or
ductwork where exhaust may be carried, or blown by the
wind, exposing others to danger.
ARO1770L
Figure 12

Safety OP000468
1-22
Emergency Exit
This machine is equipped with a glass breaking tool. It is
behind the operator seat in the upper left corner of the
cabin. This tool can be used in case of an emergency
situation that requires the breaking of glass to exit from the
operator's cabin. Grip the handle firmly and use the sharp
point to break the glass.

WARNING! FG006340
Figure 13
Protect your eyes when breaking the glass.

Safety OP000468
1-23
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. If there is a lot of
dust and sand on the work site, spray water before starting
operations.
If you need to operate on a street, protect pedestrians and
cars by designating a person for work site traffic duty or by
erecting fences and posting "No Entry" signs around the
work site.
Erect fences, post "No Entry" signs, and take other steps to
prevent people from coming close to or entering the work
site. If people come close to a moving machine, they may
be hit or caught by the machine, and this may lead to
serious personal injury or death.
DANGER
No Entry
Waterlines, gas lines, phone lines and high-voltage electrical
FG007481
lines may be buried under the work site. Contact each utility
Figure 14
and identify their locations. Be careful not to damage or cut
any of these lines.
Check the condition of the riverbed, and the depth and flow
of the water before operating in water or crossing a river.
NEVER work in water that is more than the permissible
water depth.
Any object in vicinity of boom could represent a potential
hazard, or cause the operator to react suddenly and cause
an accident. Use a spotter or signal person when working
near bridges, phone lines, work site scaffolds, or other
obstructions.

FG006341
Figure 15

Safety OP000468
1-24
Minimum levels of insurance coverage, work permits or
certification, physical barriers around the work site or
restricted hours of operation may be mandated by governing
authorities. There may also be regulations, guidelines,
standards or restrictions on equipment that may have to be
followed for local requirements. There may also be
regulations related to performing certain kinds of work. If
there is any question about whether your machine and work
site complies with the applicable standards and regulations
contact your local authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine FG006342
to escape. Figure 16
Avoid operating your machine too close to the edge of cliffs,
overhangs, and deep ditches. The ground may be weak in
such areas. If the ground collapses, the machine could fall
or tip over resulting in serious injury or death.
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 danger of falling rocks.

Checks Before Starting Engine

Every day before starting the engine for the first time, carry
out the following checks. If these checks are not carried out
properly, there is danger of serious injury.
Remove all wood chips, leaves, grass, paper and other
flammable materials accumulated in the engine compartment
and around the battery. They could cause a fire. Remove
any dirt from the window glass, mirrors, handrails, and steps.
Do not leave tools or spare parts laying around in the
operator's cabin. The vibration of the machine when traveling
or during operations may cause them to fall and damage or
break the control levers or switches. They may also get
caught in the gap of the control levers and cause the work
equipment to malfunction or move dangerously. This may
lead to unexpected accidents.
Check the coolant level, fuel level, and hydraulic tank oil
level, and check for clogged air cleaner and damage to the
electrical wiring.
Adjust the operator's seat to a position where it is easy to
operate the machine, and check the seat belt and mounts
for damage and wear.
Check the operation of the gauges and the angle of the mirrors,
and check that the safety lever is in "LOCKED" position.
If any abnormalities are found in the above checks, carry
out repairs immediately.

Safety OP000468
1-25
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.
Look around the work site area for potential hazards, people
or property that could be at risk while operation is in
progress.
NEVER start the engine if there is any indication that
maintenance or service work is in progress, or if a warning
tag is attached to controls in the cabin.
A machine that has not been used recently, or is being
operated in extremely cold temperatures, could require a
warm-up or maintenance service before start-up.
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.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.

Safety OP000468
1-26
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. Do not let anyone near the machine when
carrying out the checks.
• Check the operating condition of the equipment,
and the movement of the bucket, arm, boom,
travel, and swing systems.
• Check the machine for any abnormal noise,
vibration, heat, smell, or abnormality with the
gauges. Check also for leakage of air, oil, and
fuel.
• If any abnormality is found, repair the problem
immediately. If the machine is used without
repairing the problems, it may lead to unexpected
injury or failure.
• Clear all personnel from directly around machine
and from the area.
• Clear all obstacles from the machine's path.
Beware of hazards.
• Be sure that all windows are clean. Secure the
doors and the windows in the open position or in
the shut position.
• Adjust the rearview mirrors for best visibility close
to the machine. Make sure that the horn, the
travel alarm (if equipped), and all other warning
devices are working properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before
operating machine.
• Before moving the machine, check undercarriage
position. The normal travel position is with idler
wheels to the front under the cabin and the drive
sprockets to the rear. When the undercarriage is
in the reversed position, the travel controls must
be operated in opposite directions.

Safety OP000468
1-27
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 HAOA190L
changing the direction of travel. Figure 17
• Sound the horn to warn people in the area.
• Check that there is no one in the area around the
machine. There are blind spots behind the
machine, so if necessary, swing the upper
structure to check that there is no one behind the
machine before traveling in reverse.
• When operating in areas that may be hazardous
or have poor visibility, designate a person to
direct work site traffic.
• Ensure that no unauthorized person can come
within the turning radius or direction of travel.
Be sure to observe the above precautions even if a travel
alarm or mirrors are installed.

Safety OP000468
1-28
Travel Precautions T R AV E L P O ST U R E

Never turn the starting switch to the "O" (OFF) position

when traveling. It is dangerous if the engine stops while the
machine is traveling. It will be impossible to operate the
steering.
Attachment control levers should not be operated while
traveling.
Do not change selected travel mode (FAST/SLOW) while
traveling.
Fold in work equipment so the outer end of the boom is as I N C O R R E CT
close to the machine as possible, and is 40 - 50 cm
(16 - 20 in) above ground.
Never travel over obstacles or slopes that will cause the
machine to tilt severely. Travel around any slope or obstacle
that causes the machine to tilt 10 degrees or more to the
right or left, or 30 degrees or more from front to rear.
Do not operate the steering suddenly. The work equipment
may hit the ground and cause the machine to lose its
balance, and this may damage the machine or structures in
FG007524
the area.
Figure 18
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 upper track rollers.
When traveling over bridges or structures on private land,
check first that the bridge or structure can withstand the
weight of the machine. When traveling on public roads,
check with the local authorities and follow their instructions.

Safety OP000468
1-29
Traveling on Slopes
Never jump onto a machine that is running away to stop it.
There is danger of serious injury.
Traveling on slopes could result in the machine tipping over
or slipping. 20 ~
30 C
m
On hills, banks or slopes, carry the bucket approximately
20 - 30 cm (8 - 12 in) above the ground. In case of an
emergency, quickly lower the bucket to the ground to help
stop the machine.
Do not travel on grass, fallen leaves, or wet steel plates.
Even slight slopes may cause the machine to slip to the
side, so travel at low speed and make sure that the
machine is always traveling directly up or down the slope.
Avoid changing the direction of travel on a slope. This could
result in tipping or side slipping of the machine. Cm
~ 30
When possible, operate the machine up slopes and down 20
slopes. Avoid operating the machine across the slope, when
possible.

FG007525
Figure 19

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.

FG006343
Figure 20

Safety OP000468
1-30
Do not carry out deep digging under the front of the
machine. The ground under the machine may collapse and
cause the machine to fall.
Working heavy loads over loose, soft ground or uneven,
broken terrain can cause dangerous side load conditions
and possible tipover and injury. Travel without a load or a
balanced load may also be hazardous.
Never relay on lift jacks or other inadequate supports when
work is being done. Block tracks fore and aft to prevent any
movement.
FG006344
Figure 21

When using the machine, to prevent accidents caused by

damage to the work equipment and overturning because of
an excessive load, do not use the machine in excess of its
ability (in terms of the maximum load and stability
determined by the structure of the machine).
When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death. Investigate the configuration and
ground conditions of the work site beforehand to prevent the
machine from falling and to prevent the ground, stockpiles,
or banks from collapsing. FG006345
Figure 22

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:
• When working in dark areas, attach working lights
and front lights to the machine. If necessary, set
up lighting at the work site.
• Stop operations when the visibility is poor, such
as in fog, mist, snow, and rain. Wait for the
visibility to improve to a level which causes no
problems for the operation.

Safety OP000468
1-31
To avoid hitting the work equipment, always do the
following:
• When working in tunnels, on bridges, under
electrical wires, or when parking the machine or
carrying out other operations in places with limited
height, be extremely careful not to hit the bucket
or other parts.
• To prevent collisions, operate the machine at a
safe speed when working in confined spaces,
indoors, or in crowded areas.
FG006346
• Do not pass the bucket over the heads of workers Figure 23
or over the operator's cabin of dump truck.

Avoid High-voltage Cables

Serious injury or death can result from contact or proximity
to high-voltage electrical lines. The bucket does not have to
make physical contact with power lines for current to be
transmitted.
Use a spotter and hand signals to stay away from power
lines not clearly visible to the operator.

Voltage Minimum Safe Distance

6.6 kV 3 m (9' 10") FG006347

33.0 kV 4 m (13' 1") Figure 24

66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")

Use these minimum distances as a guideline only.

Depending upon the voltage in the line and atmospheric
conditions, strong current shocks can occur with the boom
or bucket as far away as 4 - 6 m (13 - 20 ft.) from the
power line. Very high voltage and rainy weather could
further decrease that safety margin.
NOTE: Before starting any type of operation near power lines
(either above ground or buried cable type), you
should always contact the power utility company
directly and work out a safety plan with them.

Safety OP000468
1-32
Operate Carefully on Snow, Ice and in
Very Cold Temperatures
In icy cold weather avoid sudden travel movements and stay
away from even slight slopes. The machine could skid off to
one side very easily.
Snow accumulation could hide or obscure potential hazards.
Use care while operating or while using the machine to
clear snow.
Warming up the engine for a short period may be
necessary, to avoid operating with sluggish or reduced
working capacity. The jolting shocks and impact loads
caused by bumping or bottoming the boom or attachment
are more likely to cause severe stress in very cold
temperatures. Reducing work cycle rate and work load may
be necessary.
When the temperature rises, frozen road surfaces become
soft, and machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare
hands. If you touch a metal surface in extremely cold
weather, your skin may freeze to the metal surface.

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. This operation is
dangerous.
If the machine has to be used on a slope, pile the soil to
FG008060
make a platform that will keep the machine as horizontal as
possible. Figure 25

In addition, lower the bucket as far as possible, keep it

pulled into the front, and keep the swing speed as low as
possible.

Safety OP000468
1-33
Parking Machine
Avoid making sudden stops, or parking the machine
wherever it happens to be at the end of the workday. Plan
so the excavator will be on firm, level ground away from
traffic and away from high walls, cliff edges and any area of
potential water accumulation or runoff. If parking on inclines
is unavoidable, block the crawler tracks to prevent
movement. Lower the bucket or other working attachment to
the ground, or to an overnight support saddle. There should
be no possibility of unintended or accidental movement.
Park machine so there is enough clearance between it and
other machines. Non-slip
support
When parking on public roads, provide fences, signs, flags,
or lights, and put up any other necessary signs to ensure
that passing traffic can see the machine clearly. Park the
machine so the machine, flags, and fences do not obstruct
traffic.
After all attachments, such as the bucket and blade, have
been lowered to an overnight storage position and all
switches and operating controls are in the "OFF" position,
the safety lock lever must be set to the "LOCKED" position. Non-slip
This will disable all pilot circuit control functions. support

Always close the door of the operator's cabin.

FG007526
Figure 26

Precautions for Traveling in Reverse

Backing up is potentially dangerous because of restricted
visibility.
Use a signalman when backing up.
• Watch for people nearby.
• Use horn or other signal to warn people nearby.
• Keep windows, mirrors and headlights clean and
good repair at all times.
FG007527
• Slow down when visibility is poor due to dust, Figure 27
heavy rain, fog, or other conditions.

Safety OP000468
1-34
Never Let Anyone Ride on Attachment
Never let anyone ride on any work attachment, such as the
bucket, crusher, grapple, or clamshell (grab bucket). There is
a danger of the person falling and suffering serious injury.

ARO1310L
Figure 28

Safety OP000468
1-35
MAINTENANCE

Warning Tag
Alert others that service or maintenance is being performed
and tag operator's cabin controls – and other machine areas
if required – with a warning notice. OSHA mandated control WARNING
lever lockout can be made with any OSHA certified lockout
DO NOT OPERATE
device and a length of chain or cable to keep the safety
lever in the fully lowered, nonactive position. when performing inspection
or maintenance
Warning tags, for controls are available from DOOSAN
190-00695
distributors.
ARO1320L
Figure 29

Clean Before Inspection or Maintenance

Clean the machine before carrying out inspection and
maintenance. This prevents dirt from getting into the
machine and also ensures safety during maintenance.
If inspection and maintenance are carried out when the
machine is dirty, it will become more difficult to locate the
problems, and also there is danger that you may get dirt or
mud in your eyes or that you may slip and injure yourself.
When washing the machine, do the following:
• Wear shoes with nonslip soles to prevent yourself
from slipping and falling on wet places.
• Wear safety glasses and protective clothing when
washing the machine with high-pressure steam.
• Take action to prevent touching high-pressure
water and cutting your skin or having mud fly into
your eyes. ARO1330L
Figure 30
• Do not spray water directly on electrical
components (sensors, connector). If water gets
into the electrical system, there is danger that it
will cause defective operation and malfunction.
Pick up any tools or hammers that are laying in the work
place, wipe up any grease or oil or any other slippery
substances, and clean the area to make it possible to carry
out the operation in safety. If the work place is left untidy,
you may trip or slip and suffer injury.

Safety OP000468
1-36
Proper Tools
Use only tools suited to the task. Using damaged, low
quality, faulty, or makeshift tools could cause personal injury.
There is danger that pieces from, chisels with crushed
heads, or hammers, may get into your eyes and cause
blindness.

HDO1037L
Figure 31

Use of Lighting
When checking fuel, oil, battery electrolyte, or window
washing fluid, always use lighting with antiexplosion
specifications. Danger of an explosion is elevated when
proper lighting equipment is not used.
If work is carried out in dark places without using lighting, it
may lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame
instead of lighting. There is danger of fire. There is also
HDO1040L
danger that the battery gas may catch fire and cause an
Figure 32
explosion.

Safety OP000468
1-37
Fire Prevention and Explosion
Prevention
All fuels, most lubricants and some coolant mixtures are
flammable. Leaking fuel or fuel that is spilled onto hot
surfaces or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked
containers and away from all unauthorized persons.
Store oily rags and other flammable material in a protective
container. HDO1015I

Do not smoke while you refuel the machine or while you are Figure 33
in a refueling area.
Do not smoke in battery charging areas or in areas the
contain flammable material.
Clean all electrical connections and tighten all electrical
connections. Check the electrical wires daily for wires that
are loose of frayed. Tighten all lose electrical wires before
you operate the machine. Repair all frayed electrical wires
before you operate the machine.
Remove all flammable materials before they accumulate on
the machine.
Do not weld on pipes or on tubes that contain flammable
fluids. Do not flame cut on pipes or on tubes that contain
flammable fluids. Before you weld on pipes or on tubes or
before you flame cut on pipes or on tubes, clean the pipes
or tubes thoroughly with a nonflammable solvent.

Safety OP000468
1-38
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.
If the coolant level in the coolant recovery tank is below the
lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the
eyes, or the mouth.
Allow cooling system components to cool before you drain
the cooling system.
Hot oil and hot components can cause personal injury. Do
not allow hot oil or hot components to contact the skin.
Remove the hydraulic tank filter plug only after the engine
has been stopped. Make sure that the hydraulic tank filter
plug is cool before you remove it with your bare hand.
Remove the hydraulic tank filter plug slowly to relieve
pressure.
Relieve all pressure in the hydraulic oil system, in the fuel
system, or in the cooling system before you disconnect any HAAE1980
lines, fittings, or related items. Figure 34
Batteries give off flammable fumes that can explode.
Do not smoke while you are checking the battery's
electrolyte levels.
Electrolyte is an acid. Electrolyte can cause personal injury.
Do not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses when you work on batteries.

Safety OP000468
1-39
Welding Repairs
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.
The qualified welder must do the following:
• To prevent explosion of the battery, disconnect
the battery terminals and remove batteries.
• To prevent generation of gas, remove the paint
from the location of the weld.
• If hydraulic equipment, piping or places close to
them are heated, a flammable gas or mist will be
generated and there is danger of it catching fire.
To avoid this, never subject these places to heat.
• Do not weld on pipes or on tubes that contain
flammable fluids. Do not flame cut on pipes or on
tubes that contain flammable fluids. Before you
weld on pipes or on tubes or before you flame
cut on pipes or on tubes, clean the pipes or
tubes thoroughly with a nonflammable solvent.
• If heat is applied directly to rubber hoses or
piping under pressure, they may suddenly break,
so cover them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and provide a fire
extinguisher.

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. Put up a fence
around the attachments and take other measures to prevent HDO1041L
unauthorized persons from entering. Figure 35

Safety OP000468
1-40
Precautions When Working on Machine
When carrying out maintenance operations on the machine,
keep area around your feet clean and tidy to prevent falls.
Always do the following:
• Do not spill oil or grease.
• Do not leave tools laying about.
• Watch your step when walking.
Never jump down from the machine. When getting on or off
ARO1380L
the machine, use the steps and handrails, and maintain a
Figure 36
three-point contact (both feet and one hand or both hands
and one foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when working on
the hood or covers, never use any area except the area
equipped with nonslip pads.

Track Tension Adjustments Require

Caution
Never turn out the track tension grease fitting nut. To
release pressure from the crawler frame track tension
assembly, you should NEVER attempt to disassemble the
track adjuster or attempt to remove the grease fitting or
valve assembly.
Keep your face and body away from the valve. Refer to the
track adjustment procedure in the Operator and Maintenance
HAOA110L
Manual or Shop Manual.
Figure 37

Supports and Blocking for Work

Equipment
Do not allow weight or equipment loads to remain
suspended.
Lower everything to the ground before leaving the operator's
seat.
Do not use hollow, cracked or unsteady wobbling supports.
Do not work under any equipment supported only by a lifting
HDO1042L
jack.
Figure 38

Safety OP000468
1-41
Action When Abnormality Is Found
During Inspection
If any abnormality is found during inspection, always carry
out repairs. In particular, if the machine is used when there
are still problems with the brake or work equipment systems,
it may lead to serious injury.
If necessary depending on the type of failure, please contact
your DOOSAN distributor for repairs.

Precautions with High-pressure Lines,

Tubes and Hoses X
When inspecting or replacing high-pressure piping or hoses,
check to verify that the pressure has been released from the
circuit. Failure to release the pressure may lead to serious
injury. Always do the following:
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized X
components can be difficult to see but pressurized
oil has enough force to pierce the skin and cause
serious injury. Always use a piece of wood or
cardboard to check for suspected hydraulic leaks.
Never use your hands or expose your fingers.
• Do not bend high-pressure lines. Do not strike
high-pressure lines. Do not install lines, tubes or
hoses that are bent or damaged.
• Make sure that all clamps, guards and heat
shields are installed correctly to prevent vibration,
rubbing against other parts, and excessive heat
during operation.
HDO1045I
– If any of the following conditions are found, Figure 39
replace the part.
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or
exposure of strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable
parts of hose.
– Foreign material is embedded in the
covering.
– Hose end is deformed.
NOTE: Refer to “Hose In-service Lifetime Limit
(European Standard ISO 8331 and
EN982 CEN)” on page 4-38, for additional
European regulations.

Safety OP000468
1-42
Waste Materials
Physical contact with used motor oil may pose a health risk.
X
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:
• Never dump waste oil in a sewer system, rivers,
HAOA470L
etc.
Figure 40
• Always put oil drained from your machine in
containers. Never drain oil directly onto the
ground.
• Obey appropriate laws and regulations when
disposing of harmful materials such as oil, fuel,
solvent, filters, and batteries.

Safety OP000468
1-43
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.
• When working with batteries, ALWAYS wear
safety glasses and rubber gloves.
• If you spill battery electrolyte on yourself or your
clothes, immediately flush the area with water.
• If battery electrolyte gets into your eyes, flush
them immediately with large quantities of water
and see a doctor at once.
• If you accidentally drink battery electrolyte, drink a
large quantity of water or milk, raw egg or
vegetable oil. Call a doctor or poison prevention
center immediately.
• When cleaning the top surface of the battery,
wipe it with a clean, damp cloth. Never use
gasoline, thinner, or any other organic solvent or
detergent.
• Tighten the battery caps securely.
• If the battery electrolyte is frozen, do not charge
the battery or start the engine with power from
another source. There is danger that the battery
may catch fire.
Figure 41
• When charging the battery or starting with power
from another source, let the battery electrolyte
melt and check that there is no leakage of battery
electrolyte before starting the operation.
• Always remove the battery from the machine
before charging.

Safety OP000468
1-44
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.
HAOA310L
• When boost starting from another machine or Figure 42
vehicle do not allow the two machines to touch.
Wear safety glasses or goggles while required
battery connections are made.
• Connect positive cable first when installing cables
and disconnect the negative cable first when
removing them. The final cable connection, at the
metal frame of the machine being charged or
boost started, should be as far away from the
batteries as possible.

Safety OP000468
1-45
TOWING

Precautions When Towing

Cloth
If any mistake is made in the method of selecting or
inspecting the towing wire or in the method of towing, it may
lead to serious personal injury. Always do the following:
• Always use the method of towing given in this
Operation and Maintenance Manual. Do not use
any other method.
Towing Wire
• Use leather gloves when handling the wire rope.
• When carrying out the preparation work for towing
with two or more workers, determine the signals
to use and follow these signals correctly.
• Always fit the towing rope to the left and right
hooks and secure in position.
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 machine during the towing operation. Figure 43

• It is dangerous to carry out towing on slopes, so

select a place where the slope is gradual. If there
is no place where the slope is gradual, carry out
operations to reduce the angle of the slope before
starting the towing operation.
• When towing a problem machine, always use a
wire rope with a sufficient towing capacity.
• Do not use a frayed, kinked rope or a rope with
any loss of diameter.
• Do not use the lightweight towing hook for towing
another machine.

Safety OP000468
1-46
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.
Partial disassembly or teardown of the excavator may be
necessary to meet travel restrictions or particular conditions
at the work site. See the Shop Manual for information on
partial disassembly.
Refer to the Transportation and Shipping section of this
Operation and Maintenance Manual for information on
loading, unloading and towing.

Safety OP000468
1-47
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.
When changing the hoses record the part numbers of
the hoses to factory log book.
Do the service job under the company's serviceman. Figure 44

WARNING!
All rated lift capacities are based on the machine and
the load both remaining level at all times. DO NOT
EXCEED THE RATED LIFT CAPACITY. Lifting loads
greater than those shown in the rated capacity tables
can cause catastrophic equipment failure and/or
structural collapse of the machine.

To operate safely the excavator should be on a firm, level

and uniformly supporting surface. The operator is expected
to make due allowance for all specific work site and lift
related conditions, and respond to changes in those
conditions that could pose a hazard. The following could all
cause hazardous conditions and accidents or injuries:
• Soft or uneven ground.
• Unlevel terrain.
• Side loads.
• Modifications or poor maintenance of the
excavator.
• Failure to lift squarely over the end or over the
side of the machine.
When a load is in the air, the operator must remain alert.
• Avoid side loads that may be caused by uneven
slings, traveling with the load or swinging too quickly.
• The load can become unbalanced if the hook line
is twisted and starts to rotate. If the surface area
of the load is large enough, wind gusts can
create side loads.

Safety OP000468
1-48
 • Keep the bucket hook point directly over the load. Tag
lines on opposite sides of the load can help maintain
greater stability against side loads and wind gusts.
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.
The following weight loads are in compliance with SAE
(J1097) and ISO applicable, recommended standards for
hydraulic excavators performing lifting operation on a firm
supporting surface. An asterisk (*) next to the lift rating
indicates rated load does not exceed 87% of hydraulic
capacity. All other ratings have been determined not to
exceed 75% of tipping capacity.
Do not attempt to lift or hold any load that exceeds rated
load capacity at the specified distances (from the machine's
rotation center line and height - see "lift radius" and "lift
height" in the reference drawing, Figure 45).

Centerline Lifting Radius

of Rotation

Lifting
Point Lifting
Point
Height

Ground Line (Machine Supporting Surface)

FG008061
Figure 45

The weight of slings and any auxiliary lifting device (and/or

the weight difference of any attachment heavier than
standard configuration) must be deducted from the rated lift
capacity to determine allowable net lifting load. The lift point
should be on the back of the bucket, as shown in Figure
45.

Safety OP000468
1-49
 A

B
WITHOUT DOZER

METRIC
A(m) 2 3 4 MAX. REACH

A(m)
B(m)
4 * 0.77 * 0.77 2.76
* *
3 0.67 0.67 0.48 0.47 3.76

2 0.70 0.69 0.43 0.42 0.39 0.38 4.21

1 0.67 0.65 0.42 0.41 0.36 0.36 4.34

0 (GROUND) 1.23 1.18 0.64 0.63 0.41 0.40 0.38 0.38 4.18

-1 1.25 1.20 0.64 0.63 0.47 0.46 3.68

*
-2 1.30 1.25 0.84 0.83 2.59

FEET
A (ft) 6’ 8’ 10’ 12’ 14’ MAX. REACH

B (ft) A (ft)

12’ 1.54 1.51 1.41 1.38 10’ 6"

10’ * 1.48 * 1.48 1.12 1.10 1.08 1.06 12’ 3"

8’ 1.54 1.51 1.12 1.10 0.92 0.91 13’ 4"

6’ 2.16 2.10 1.50 1.47 1.11 1.09 0.84 0.83 13’ 12"

4’ 2.04 1.99 1.45 1.42 1.08 1.06 0.83 0.82 0.81 0.79 14’ 3"

2’ 1.97 1.92 1.41 1.37 1.06 1.04 0.82 0.81 0.81 0.79 14’ 2"

0 (GROUND) 1.95 1.90 1.38 1.35 1.04 1.02 0.84 0.83 13’ 9"

-2’ 3.20 3.07 1.95 1.90 1.38 1.35 1.04 1.02 0.94 0.92 12’ 11"

-4’ 3.25 3.12 1.98 1.92 1.39 1.36 1.13 1.10 11’ 6"

-6’ 3.32 3.19 2.03 1.97 1.59 1.56 9’ 4"

FG007530

Safety OP000468
1-50
 A

B
WITH DOZER
METRIC
A(m) 2 3 4 MAX. REACH

A(m)
B(m)
4 * 0.77 * 0.77 2.76
* * *
3 0.67 0.67 0.73 0.47 3.76

2 * 0.88 0.69 * 0.75 0.41 * 0.74 0.38 4.21

1 * 1.18 0.65 * 0.84 0.40 * 0.78 0.36 4.34

0 (GROUND) * 1.29 1.18 * 1.34 0.63 * 0.89 0.39 * 0.82 0.38 4.18
* * *
-1 2.17 1.20 1.26 0.63 0.87 0.46 3.68

-2 * 1.31 1.25 * 0.84 0.83 2.59

FEET
A (ft) 6’ 8’ 10’ 12’ 14’ MAX. REACH

B (ft) A (ft)

12’ * 1.56 1.51 * 1.64 1.38 10’ 6"

10’ * 1.48 * 1.48 * 1.58 1.10 * 1.61 1.06 12’ 3"

8’ * 1.67 1.51 * 1.59 1.10 * 1.62 0.91 13’ 4"

6’ * 2.61 2.10 * 2.02 1.47 * 1.75 1.09 * 1.65 0.83 13’ 12"

* 3.46 * 2.42 * 1.95 * 1.71 * 1.70

4’ 1.99 1.42 1.06 0.82 0.79 14’ 3"

2’ * 3.97 1.92 * 2.74 1.37 * 2.13 1.04 * 1.78 0.81 * 1.75 0.79 14’ 2"

0 (GROUND) * 4.08 1.90 * 2.89 1.35 * 2.22 1.02 * 1.81 0.83 13’ 9"

-2’ * 4.42 3.07 * 3.93 1.90 * 2.85 1.35 * 2.16 1.02 * 1.88 0.92 12’ 11"

-4’ * 5.07 3.12 * 3.51 1.92 * 2.56 1.36 * 1.93 1.10 11’ 6"

-6’ * 3.77 3.19 * 2.62 1.97 * 1.91 1.56 9’ 4"

FG007553

Safety OP000468
1-51
 A

B
WITHOUT DOZER

METRIC
A(m) 2 3 4 MAX. REACH

A(m)
B(m)
* 0.71 * 0.71 2.95
4

3 0.46 0.45 3.89

2 0.71 0.69 0.43 0.42 0.37 0.36 4.33

1 0.67 0.65 0.42 0.40 0.35 0.34 4.45

0 (GROUND) 1.22 1.18 0.64 0.62 0.41 0.40 0.36 0.36 4.30

-1 1.24 1.19 0.64 0.62 0.44 0.43 3.82

-2 1.28 1.24 0.74 0.73 2.80

FEET
A (ft) 6’ 8’ 10’ 12’ 14’ MAX. REACH

B (ft) A (ft)

12’ * 1.39 * 1.39 1.30 1.28 11’ 0"

10’ * 1.35 * 1.35 1.13 1.11 1.02 1.00 12’ 8"

8’ 1.55 1.52 1.13 1.11 0.88 0.86 13’ 8"

6’ 2.17 2.11 1.50 1.47 1.11 1.09 0.84 0.83 0.80 0.79 14’ 4"

4’ 2.06 2.00 1.45 1.42 1.08 1.06 0.83 0.81 0.77 0.76 14’ 7"

2’ 1.97 1.92 1.40 1.37 1.05 1.03 0.82 0.80 0.77 0.75 14’ 6"

0 (GROUND) * 2.55 * 2.55 1.94 1.89 1.37 1.34 1.04 1.02 0.81 0.80 0.80 0.79 14’ 1"

-2’ 3.17 3.05 1.94 1.89 1.37 1.34 1.03 1.01 0.88 0.87 13’ 3"

-4’ 3.22 3.09 1.96 1.90 1.38 1.35 1.05 1.03 11’ 12"

-6’ 3.29 3.16 2.00 1.95 1.43 1.40 9’ 12"

FG007556

Safety OP000468
1-52
 A

B
WITH DOZER

METRIC
A(m) 2 3 4 MAX. REACH

A(m)
B(m)
4 * 0.71 * 0.71 2.95
*
3 0.69 0.45 3.89

2 * 0.82 0.69 * 0.71 0.42 * 0.71 0.36 4.33

1 * 1.14 0.65 * 0.81 0.40 * 0.74 0.34 4.45

0 (GROUND) * 1.46 1.18 * 1.33 0.62 * 0.88 0.40 * 0.79 0.36 4.30
* * *
-1 2.26 1.19 1.28 0.62 0.85 0.43 3.82

-2 * 1.49 1.24 * 0.86 0.73 2.80

FEET
A (ft) 6’ 8’ 10’ 12’ 14’ MAX. REACH

B (ft) A (ft)

*
12’ 1.39 * 1.39 * 1.52 1.28 11’ 0"

10’ * 1.35 * 1.35 * 1.45 1.11 * 1.51 1.00 12’ 8"

8’ * 1.55 1.52 * 1.50 1.11 * 1.53 0.86 13’ 8"

6’ * 2.40 2.11 * 1.91 1.47 * 1.67 1.09 * 1.57 0.83 * 1.57 0.79 14’ 4"

* 3.28 * 2.32 1.42 * 1.89 * 1.66 0.81 * 1.62

4’ 2.00 1.06 0.76 14’ 7"

2’ * 3.87 1.92 * 2.67 1.37 * 2.08 1.03 * 1.75 0.80 * 1.68 0.75 14’ 6"

0 (GROUND) * 2.55 * 2.55 * 4.07 1.89 * 2.86 1.34 * 2.20 1.02 1.76 0.80 * 1.74 0.79 14’ 1"

-2’ * 4.37 3.05 * 3.98 1.89 * 2.87 1.34 * 2.18 1.01 * 1.82 0.87 13’ 3"
* 5.34 * 3.63 * 2.64 * 1.89
-4’ 3.09 1.90 1.35 1.03 11’ 12"
* 4.16 * 2.87 *
-6’ 3.16 1.95 1.92 1.40 9’ 12"

FG007555

Safety OP000468
1-53
Safety OP000468
1-54
 OP000469

2Operating Controls
The "Operating Controls" section presented here consists of
the following groups:
1. “Component Locations” on page 2-2
2. “Operator's Area” on page 2-4
3. “Operational Controls and Panels” on page 2-6
4. “instrument Panel” on page 2-13
5. “Stereo (Optional)” on page 2-18
6. “Fuse boxes” on page 2-19
7. “Miscellaneous Electrical Devices” on page 2-20
8. “Heating and Air Conditioning System (Optional)” on
page 2-21
9. “Seat Adjustment” on page 2-24
10. “Seat Belt” on page 2-24
11. “Front Windows” on page 2-26
12. “Door Side Latch” on page 2-28
13. “Cabin Storage Compartments” on page 2-28
14. “Hanger” on page 2-29
15. “Cup Holder” on page 2-29
16. “Emergency Glass Breaking Tool” on page 2-29

Each group is explained with a point location drawing or

photo and a brief description of each control, switch, gauge
or valve.
Indicator lights work besides the gauges on the instrument
panel. The operator should monitor machine pressure on the
instrument panel along with indicator lights. These lights will
only show that there is a problem.

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 OP000469

2-1
COMPONENT LOCATIONS

13 25 3 1

15

4
10
5
26

12 2
6
11
14 7

9 8

19

16 20 22 21 24 18 23 17
FG007483

Figure 1

Operating Controls OP000469

2-2
 Reference Reference
Description Description
Number Number
1 Boom 14 Counterweight
2 Boom Cylinder 15 Seat
3 Arm Cylinder 16 Rubber Crawler (Track)
4 Arm 17 Blade
5 Bucket Cylinder 18 Blade Cylinder
6 Bucket Linkage 19 Travel Motor
7 (Dump) Linkage 20 Lower Roller
8 Bucket 21 Idler
9 Swing frame 22 Track Spring
10 Cover 23 Swing Bracket
11 Fuel Tank 24 Swing Cylinder
12 Hydraulic Oil Tank 25 Attachment Control Levers
13 Canopy 26 Air breather

Operating Controls OP000469

2-3
OPERATOR'S AREA

9
14

1
7
15

10

12

11

13
8

FG007488

Figure 2

Operating Controls OP000469

2-4
 Reference Reference
Description Description
Number Number
1 Instrument Panel 8 Storage Compartment
(See page 2-12) (See page 2-28)
2 Cigar Lighter (Optional) 9 Air Conditioner Unit (Optional)
(See page 2-10) 10 Heater (Optional)
3 Travel Levers 11 Fuse Box
(See page 3-15) (See page 2-19)
4 Right-hand Work Lever 12 Left-hand Work Lever (Joystick)
(Joystick) (See page 3-22)
(See page 3-22)
13 Safety Lever
5 Engine Speed Control Lever (See page 3-13)
(See page 2-8)
14 Cup Holder
6 Starter Switch (See page 2-29)
(See page 2-8)
15 Blade Lever
7 Seat
(See page 2-24)

Operating Controls OP000469

2-5
OPERATIONAL CONTROLS AND
PANELS

6 5 11

7 1 2 3 4 8 9 10
FG007489

Figure 3

Operating Controls OP000469

2-6
 Reference Reference
Description Description
Number Number
1 Starter Switch 7 Cigar Lighter (Optional)
2 Travel Speed Selector Switch 8 Windshield Washer Switch
3 Work Light Switch (Optional)
4 Quick Clamp Switch (Optional) 9 Wiper Switch (Optional)
5 Travel Alarm Switch (Optional) 10 Heater Switch (Optional)
6 Warning Light Switch (Optional) 11 Horn Switch

Operating Controls OP000469

2-7
1. Starter Switch
O I
A four-position starter switch is used to start or shut
down engine for equipment operation.
O. Turning the switch to this position turns the
engine "OFF" along with its electrical system. In
this position the engine is "OFF" but the interior
cabin light is functional.
I. Turning the switch to this position turns the
engine electrical system "ON." The battery FG001364
warning light and the oil pressure indicator light
Figure 4
should be "ON".

. Moving switch to this position will crank engine.

When engine starts, release key and allow it to
return to "I" (ON) position. Do not operate the
starter switch for more than fifteen seconds at a
time. This will help prevent damage to starter.

WARNING!
DO NOT USE STARTING FLUIDS. The preheat
system could cause the starting fluid to explode.

. Preheat position. Used to aid engine starting in

cold weather. When key is in this position, engine
preheater is operating. When preheat indicator
light turns "ON" engine preheat cycle is complete.
Immediately turn key to crank position and start
engine. This light turns "ON" after fifteen seconds
when the starter switch is turned to the preheating
position.

2. Travel Speed Selector Switch

WARNING!
O
Do not operate the travel speed selector switch
when unit is in motion. Temporary loss of control
could result.
I
O. In this position, "LOW" travel speed is selected. HDO2022I

I. In this position, "HIGH" travel speed is selected. Figure 5

Operating Controls OP000469

2-8
3. Work Light Switch
This switch is used to control the work lights and the
cabin work lights, if unit is equipped with them.
O. In this position, all lights are turned "OFF." O
I. In this position, the work lights and all instrument I
panel lights and control switch lights are turned
"ON"
II
II. In this position, the work lights and all instrument
panel lights and control switch lights and the front HA3O2014
cabin work lights on the front top are turned "ON." Figure 6

4. Quick Clamp Switch (Optional)

Clamp releasing for interchangeable attachments 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. FG007494
The warning buzzer will sounds and the quick clamp Figure 7
indicator light will turn "ON" while the switch is in " ,"
(UNLOCKED) position.
NOTE: To move the switch, pull up on the toggle
and then move it into the "UNLOCKED"
position.

CAUTION!
When the attachment is still connected to the
machine, while the switch is in the " "
(UNLOCKED) position, do not operate the machine
or the attachment might fall to the ground. It would
cause personnel injuries.

Operating Controls OP000469

2-9
5. Travel Alarm Switch (Optional)
If unit is equipped with a travel alarm buzzer, push this
switch to active it, whenever traveling.
O. In this position, the travel alarm system is turned O
"OFF."
I. In this position, the travel alarm will sound while I
traveling.

AXO1150L
Figure 8

6. Warning Light Switch (Optional)

If unit is equipped with a warning light, push this switch
to activate it.
O. In this position, the warning light is turned "OFF." O
I. In this position, the warning light turns "ON" and
will start flashing.
I
HDO2028I

Figure 9

7. Cigar Lighter (Optional)

Push the lighter all the way into the socket and release
your hand. After pushing it in, it will be ejected when it
is heated. If it does not eject after a short time, pull it
out and have it serviced. 12V

CAUTION!
HA0O2037
Be careful when you handle the cigar lighter
because of its radiant heat and high temperature. Figure 10

Operating Controls OP000469

2-10
8. Windshield Washer Switch (Optional)
While the windshield wiper is running, depress the
washer switch to spray windshield washer fluid onto the
windshield. Use only the proper windshield washer fluid O
in the system.
O. In this position, the washer is "OFF."
I
I. In this position, the windshield washer sprays
fluid. When released the switch returns to the "O"
(OFF) position.
HAOA740L
NOTE: Do not operate the windshield washer without Figure 11
any 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.
Use standard window cleaning fluid: SSK703

9. Wiper Switch (Optional)

O. In this position, windshield wiper is turned "OFF."
I. In this position, wiper runs at "LOW" speed.
II. In this position, wiper runs at "HIGH" speed. O
NOTE: Operating wiper without washer fluid or when I
there is sand or dirt present will damage the II
window and/or wiper.

HDO2026I

Figure 12

10. Heater Switch (Optional)

This switch is used to control the speed of the blower
fan used for heater.
O. In this position, fan is "OFF."
O
I. In this position, fan runs at "LOW" speed.
II. In this position, fan runs at "HIGH" speed.

BPO0310L

Figure 13

Operating Controls OP000469

2-11
11. Horn Switch
Press button on top of left-hand work lever (joystick) to
sound horn.

FG007495
Figure 14

Operating Controls OP000469

2-12
INSTRUMENT PANEL

4 5 9 6 7

8
10

C H

1 3 2 FG007496
Figure 15

Reference Reference
Description Description
Number Number
1 Engine Coolant Temperature 6 Engine Coolant Temperature
Gauge Warning Light
2 Fuel Gauge 7 Air Cleaner Clogged Warning
3 Hour Meter Light
4 Engine Oil Pressure Warning 8 Fuel Level Warning Light
Light 9 Preheat Indicator Light
5 Charge Warning Light 10 Quick Clamp Indicator Light

Operating Controls OP000469

2-13
1. Engine Coolant Temperature Gauge WHITE
The colored bands indicate the temperature of the
engine coolant. BLUE RED

BLUE ZONE ( ) - Indicates temperature is lower C H

than the normal operating temperature.

WHITE ZONE ( ) - Indicates temperature is within

the normal operating range.

RED ZONE ( ) - Indicates temperature is too high. FG007497

Figure 16
During operation, the pointer must be in the white
zone.
If the gauge pointer moves into the red zone, the
engine coolant temperature warning light will turn "ON".
Allow the engine to run at low idle speed until the
temperature gauge registers in the white zone again.
When the white zone is reached, allow the engine to
idle for an additional three - five minutes before
shutting down the engine. If not allowed to idle, heat
surge may develop which will damage the engine.
Allowing the engine to idle will dissipate heat. Check
the coolant level, look for a loose fan belt, inspect for
debris around radiator, and so on.

2. Fuel Gauge WHITE

Shows remaining fuel quantity in tank.

RED BLUE
BLUE ZONE ( ) - Indicates that the fuel level is full.

WHITE ZONE ( ) - Indicates a normal fuel quantity.

RED ZONE ( ) - Indicates that the fuel level is low.

If the gauge pointer moves into the red zone, the fuel
warning light will turn "ON" in the instrument panel. FG007498
Stop operation and immediately and add fuel.
Figure 17
Check the fuel level on firm, level ground.

Operating Controls OP000469

2-14
3. Hour Meter
The hour meter is used to indicate the total number of
running hours on the engine. The meter will flash every
four seconds when the engine is running to indicate
that it is functioning properly.

Figure 18

4. Engine Oil Pressure Warning Light

This indicator light will turn "ON" when the engine
starter switch is turned "ON," and should go "OFF"
after the engine starts.
For example, if the engine oil pressure becomes too
low, the light will turn "ON". If this happens, shut the
engine down immediately and determine the cause of
the problem. If you continue to work when this light is
"ON," it will result in serious engine damage.
HAOA620L
Figure 19
CAUTION!
If you continue to work when this light is "ON," it
will result in serious engine damage.

5. 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.

HAOA610L
Figure 20

Operating Controls OP000469

2-15
6. Engine Coolant Temperature Warning
Light
This indicator light will turn "ON" when coolant
temperature rises excessively.

CAUTION!
When this light turns "ON," immediately stop work.
HAOD350L
Allow the engine to run at low idle speed until the
Figure 21
temperature gauge registers in the "WHITE" zone
again. When the white zone is reached, allow the
engine to idle for an additional three - five minutes
before shutting down the engine. If not allowed to
idle, heat surge may develop which will damage the
engine. Allowing the engine to idle will dissipate
heat. Check the coolant level, look for a loose fan
belt, inspect for debris around radiator, and so on.

7. Air Cleaner Clogged Warning Light

This indicator light will turn "ON" when the air cleaner
filter is clogged
When it comes "ON," clean or replace the element as
necessary. After the air cleaner filter has been
serviced, if you place the starter switch in the "O"
position and then "I" position, this indicator light turns
"OFF."

Figure 22

8. Fuel Level Warning Light

This indicator light turns "ON" when the remaining fuel
is about 10 liters (2.64 U.S. gal) or less.
When this indicator light turns "ON," fill the tank
immediately.

Figure 23

Operating Controls OP000469

2-16
9. Preheat Indicator Light
This indicator light will turn "ON" when preheating is
completed.
This light turns "ON" after fifteen seconds when the
starter switch is turned to the preheating position.

Figure 24

10. Quick Clamp Indicator Light

This indicator light will turn "ON" when the quick clamp
switch is in the " " (UNLOCKED) position.

FG007493
Figure 25

Operating Controls OP000469

2-17
STEREO (OPTIONAL)
Before operating the stereo, read operation manual enclosed with
stereo.

3 1 9 8 2 5, 6

AST

AM/FM CD TAPE SOUND SCAN

-
ON O FFV 2 RPT
S
H 1 3 UP
OL
PU

TUNE

4 INT 5 RDM 6 DN

1 4 10 7 FG007499
Figure 26

Reference Reference
Description Description
Number Number
1 Power/ Volume Control 7 Preset Station
2 Sound Mode Selection 8 Tape Ejection
3 Band Selection 9 Tape Loading Slot
4 Tuning Up / Down 10 LCD
5,6 Scan Function / Auto Store

Operating Controls OP000469

2-18
FUSE BOXES
Fuses prevent electrical devices from overloading or
shorting. There is a fuse box in the electric box which is
under the seat.
A decal attached to the fuse box's cover indicates the
function and amperage of each fuse.
Spare fuses are mounted on the inside of fuse box's cover.
(One each of a 10A, 15A, 20A and 30A.)
Change a fuse if the element separates. If the element of a
new fuse separates, check the circuit and repair the circuit.
FG007500
Figure 27
CAUTION!
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.

Fuse Identification

Fuse Box
No.
Name Capacity
1 Rotating Beacon 10A
2 Spare 10A
3 Horn, Travel Alarm, Fuel Pump 10A
4 Quick Clamp, High-speed 10A
5 Cigar Lighter 15A
6 Wiper, Washer, Stereo 15A
7 Pilot Cut Off 15A
8 Spare 30A
FG007491
9 Air Conditioner, Compressor 20A
Figure 28
10 Heater 15A
11 Condenser 15A
12 Working Light, Head Light 30A
13 Gauge Panel 10A
14 Cabin Light, Hour Meter 10A

Operating Controls OP000469

2-19
MISCELLANEOUS ELECTRICAL
DEVICES

Cabin Light
A light is installed on the left side 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.

FG007501
Figure 29

Pilot Cutoff Switch

When the safety lever is put into the "LOCK" position, the
switch deactivates the work and travel levers. With the work
and travel levers deactivated, no digging/operational work
can be done.

FG007502
Figure 30

Fusible Link
A fusible link is in the engine compartment.
A
If the engine does not crank, first check that the starter
switch is turned "ON" and that no power is available (No
indicator lights will light.). Check that the "A" portion (Figure
31) of the fusible link is not broken or burned through.
Replace the fusible link if damage and investigate cause.

WARNING! Figure 31
HAAE2120

When changing the fusible link, replace the fusible link

with the same capacity part. Otherwise, a fire could
break out in the wiring harness and/or other
components of the circuit. Always use original DOOSAN
parts.

Operating Controls OP000469

2-20
HEATING AND AIR CONDITIONING
SYSTEM (OPTIONAL)

Location of Vents

Air- Conditioner

Heater
FG007503
Figure 32

The heater is installed on the right side of the operator's cabin.

The air conditioner is installed on the back side of the
operator's seat.
If necessary, the operator can control inner temperature
using the temperature control switches installed on the right
side of the operator's cabin and on the back side of the
operator's seat.

Operating Controls OP000469

2-21
Control Switches

1. Fan Speed Selector Switch of Air Conditioner

This Switch is used to control the speed of the blower
fan used for air conditioner.

In this position, fan runs at "LOW" speed

In this position, fan runs at "INTERMEDIATE"

speed.

In this position, fan runs at "HIGH" speed.

FG007504
Figure 33

2. Temperature Control Switch

When the air conditioner is in operating, operator can
control the coming out air temperature from the air
outlets.
Clockwise, Lowers the temperature.
Counter Clockwise, Raises the temperature.

FG007505
Figure 34

3. Heater Switch
This switch is used to control the speed of the blower
fan used for heater.
O. In this position, fan is "OFF." O
I. In this position, fan runs at "LOW" speed.
II. In this position, fan runs at "HIGH" speed.

BPO0310L
Figure 35

Operating Controls OP000469

2-22
Additional Operating Instructions
Operate the air conditioner from 20 - 30 minutes a week to
circulate the refrigerant in the system.
NOTE: The blower switch should be on "I" position.
If operating the air conditioner or heater for a long time, and
when smoking, vent the air to the outside to prevent
irritation to eyes.
The air-conditioning system not only cools indoor air but it
also removes dust and moisture from the cabin.
If the system is operated when the windshield is frosted or
fogged over, the unit will remove the moisture so normal
visibility is possible.

WARNING!
Do not remove the refrigerant even in cold weather.

Operating Controls OP000469

2-23
SEAT ADJUSTMENT

1. Front/rear adjustment
Pulling up the adjustment lever (1, Figure 38) allows
the seat to be moved forward and backward over a
range of 210 mm (8.27 in).

2. Backrest Adjustment
Lifting up the adjustment lever (2, Figure 38) under the
front of the seat adjusts the seat back to obtain the
1 2
desired backrest angle.
3
2 3

3. Suspension Adjustment 1

The seat is adjusted for the driver's weight with the BTO0080L
seat empty. The adjustment is made by pulling out the Figure 36
actuator lever (3, Figure 38). To read off the current
seating pull the actuator leave out until there is a slight
resistance, pulling the actuator lever out of the end
stop will return the setting to 50 kg.

SEAT BELT

WARNING!
Seat belt is for operator's safety and should always
be worn. Before driving machine, adjust seat to
desired position for maximum comfort and machine
control, then fasten seat belt. Seat belts must be
worn across pelvic region and adjusted snugly to
lessen chance and severity of injury in event of an
accident. Never fasten a seat belt across abdomen.
Under no circumstance should operator be standing
in cabin when operating wheel loader.
Do not adjust seat position while vehicle is moving
because a loss of control may result. Stop
machine, apply parking brake, and then adjust seat.
Always, check condition of seat belt and belt
bracket before fastening it. Do not use it with
twists in it. Replace belt or bracket if damaged or
worn.

Operating Controls OP000469

2-24
 Seat Belt Locking and Unlocking
Insert belt end (1, Figure 37) into the buckle (2). Pull
the belt to check that belt end is locked into buckle.
Adjust belt length so it is comfortably tight against the
operator's pelvic region (hipbone).

HAOB140L
Figure 37

Press the button (3, Figure 38) in the center of buckle

(2) and pull out belt (1) to unlock.

HAOB150L
Figure 38

Operating Controls OP000469

2-25
FRONT WINDOWS

WARNING!
When leaving operator's seat, set the safety lever to
"LOCK" position (Figure 39), if not a serious accident
could occur by accidentally moving the work levers.

Front Upper Window

FG007539
The front upper window can be housed in the cabin's Figure 39
ceiling.

Opening the Window

WARNING!
When stowing front window in the cabin roof, make
sure both release levers (1, Figure 40) are latched. 1

1. Lower bucket to ground.

2. Set safety lever (Figure 39) on "LOCK." FG007540
3. Shut down engine by turning key to "O" (OFF) position. Figure 40

4. Turn the lock levers (1, Figure 40) towards middle of

window to release the lock.
5. Holding the lock levers pull window up and then push
it back. Turn the levers to outside to lock window.
6. Check that lock levers are securely latched in the lock
position.
NOTE: When the front upper window is open, never
extend your head or body through the window
frame.
NOTE: If the window happens to fall with a strong
impact against the machine, while some part of
your body is extended out of the cabin, it may
result in bodily injury.

Operating Controls OP000469

2-26
Closing the Window

WARNING!
Be careful that your hands are not caught in window
frame. 1

1. Lower bucket to ground.

2. Set safety lever (Figure 39) on "LOCK," and shut down FG008066
engine. Figure 41
3. Holding lock levers (1, Figure 41) of front window with
left and right-hand, turn the lock levers towards outside
edge of window to release the lock.
4. Push window forward, and lower it slowly.
5. When the bottom of the window reaches the top of the
front bottom window, push the front window forward.
Turn the lock levers towards frame to engage the lock.
6. Check that lock levers are securely latched in the lock
position.

Front Bottom Window

1
The front bottom window can be removed and stored in the
rear of the cabin.
1. After stowing the front upper window in the cabin
ceiling, remove bottom window (1, Figure 42) from
cabin in direction of the arrow.

FG007541
Figure 42

2. Set bottom window in rubber holders (2, Figure 43)

behind operator's seat. Secure window with left and
right knobs (3) with push button (4).
4

3
WARNING!
Never have wet hands when handling a window. 2
Never drop window or let it come into contact with
other parts of the machine.
FG007542
Figure 43

Operating Controls OP000469

2-27
DOOR SIDE LATCH
1. The door side latch (1, Figure 44) is used to secure
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.

1
FG007543
Figure 44

2. To release door from side of cabin, push the latch

lever (2, Figure 45) down. The latch lever is to the left
of the operator's seat.

FG000673
Figure 45

CABIN STORAGE
COMPARTMENTS
The large compartment (1, Figure 46) is for storing
nonperishable items.

FG007545
Figure 46

There is a separate small tray (2, Figure 47) on the right

side of operator's seat.
2

FG007546
Figure 47

Operating Controls OP000469

2-28
HANGER
A hanger (1, Figure 48) is located on the upper left side of
the operator's cabin.

1
WARNING!
Do not hang anything that will easily fall down, or will
impair your view out of the cabin.
FG007547
Figure 48

CUP HOLDER
There is a cup holder on the right side of the operator's
seat (Figure 49).

FG007548
Figure 49

EMERGENCY GLASS
BREAKING TOOL
The excavator is equipped with a glass breaking tool. It is to
the upper left center of the cabin. This tool can be used in
case of an emergency situation which requires the breaking
of glass to exit from the cabin. Grip the handle firmly and
use the sharp point to break the glass.

FG007549
WARNING! Figure 50

Protect your eyes when breaking the glass.

Operating Controls OP000469

2-29
Operating Controls OP000469
2-30
 OP000470

3Operation

TO HANDLE A NEW
EXCAVATOR
All DOOSAN Daewoo 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.

Hour Load
For first 50 hours of opera- Maintain about 80% load of
tion. full capacity (Engine rpm:
80% of rated rpm)
After first 50 hours of opera- Full load
tion.

If machine is used at full load before it is broken in, it may affect

the life cycle and safe running operations. This could lead to
problems later.
NOTE: 1. Check daily for leakage of coolant, fuel, engine
oil and hydraulic oil.
2. Inspect all lubricants daily, add appropriate
lubricants as required.
3. During operation, monitor all instruments and
gauges from time to time.
4. Avoid an extreme engine load.
5. Operate unit at 80% load until engine and all
other components are at operating temperature.
6. Check that work equipment is operating
normally during operation.
7. Check machine for loose parts or for damage
that may have occurred during shipping.
8. Check for loose wiring or terminals, check
gauge operation and battery electrolyte level.

Operation OP000470
3-1
Lubrication and Filters
1. Change engine oil and replace oil filter after first 50 hours
of operation.
2. Change swing reduction device oil after first 250 hours of
operation.
3. Change hydraulic oil return filter after first 250 hours of
operation.
4. Replace travel and reduction gear oil after first 250 hours of
operation.
NOTE: For the replenishment of oil or grease, refer to
“Inspection, Maintenance and Adjustment” on
page 4-1 of this manual.

STARTING AND STOPPING THE

ENGINE

Inspection Before Starting Engine

WARNING!
If a flammable materials such as leaves, paper, etc. are
allowed to accumulate on high temperature components,
such as the engine muffler and turbo, a fire may occur. Fuel,
lubricant and hydraulic oil leaks, may cause a fire. If there is
anything wrong, perform the appropriate corrective action.

Before starting engine, inspect the following items:

1. Electric system - Check for damaged electrical cables, and
loose or missing connectors.
2. Fuel system - Drain water and sediment from fuel tank and
water separator.
3. Hydraulic system - Check for hydraulic oil leaks, damaged
tubing and hoses, and interference points of components.
4. Lubrication - Perform all daily and periodic maintenance
services. Perform services according to reading shown on
hour meter.
5. Safety - Perform a machine walk-around. Make sure that
no one is under the machine or performing any
maintenance on it, before starting engine.
6. After starting machine - Check that all operational controls
and components, are in proper operating condition, and
are functioning correctly. Stop operation and correct any
malfunction before continuing work.

Operation OP000470
3-2
Operational Checks Before Starting Lock
Engine
Unlock

WARNING!
When leaving operator's seat, set the safety lever to
"LOCK" (Figure 1) position, if not a serious accident
could occur by accidentally moving the travel or work
levers. FG007538
Figure 1
1. Set safety lever on "LOCK" (Figure 1).
2. Fasten seat belt. Check for proper operation and condition.
3. Set all operation levers in "NEUTRAL."
NOTE: Be careful not to touch any switches when
starting engine.
4. Rotate the starter switch to the "I" (ON) position
(Figure 2).
O I
• Charging warning light
• Engine oil pressure warning light
• Engine coolant temperature gauge
• Fuel gauge

FG001372
Figure 2

Operation OP000470
3-3
Engine Start

WARNING!
Start the engine after sounding horn and making sure that
there are no people or obstacles in the area.

1. Perform all steps in “Operational Checks Before

Starting Engine” on page 3-3.
2. Set engine speed control lever slightly above "LOW
IDLE" (Figure 3).
3. Sound horn.

FG007557
Figure 3
" "
4. Turn starter switch to (START) position (Figure
4). Engine should start in approximately five seconds. O I
WARNING!
If the engine does not start after approximately fifteen
seconds of cranking, release the starter switch. Wait
about five minutes and repeat above step.

5. After engine has started, release key. Key will return to the FG001372-1
"I" (ON) position (Figure 4). Figure 4

6. Follow procedures in “Hydraulic System Warm-up” on

page 3-9.
7. After warming unit, check all operating indicators to make 4 3 5
sure that all engine systems (oil pressure, coolant, etc.) are
in the normal operating range. Normal indicators are:

C H

1 2 FG007558
Figure 5

Operation OP000470
3-4
 INDICATOR
No. INSTRUMENT PANEL LIGHT OR GAUGE
READING
1 Engine Coolant Temperature Gauge White
2 Fuel Gauge White
3 Charging Warning Light OFF
4 Engine Oil Pressure Warning Light OFF
5 Engine Coolant Temperature Warning Light OFF

8. 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.
9. Check for usual engine vibration and noises. If any are
heard or felt, investigate cause.
NOTE: If engine coolant temperature gauge pointer
moves into the red zone, the engine coolant
temperature warning light will turn "ON". Allow
the engine to run at low idle speed until the
temperature gauge registers in the white zone
again. When the white zone is reached, allow
the engine to idle for an additional three - five
minutes before shutting down the engine. If not
allowed to idle, heat surge may develop which
will damage the engine. Allowing the engine to
idle will dissipate heat. Check the coolant level,
look for a loose fan belt, inspect for debris
around radiator, and so on.

Operation OP000470
3-5
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.

1. Perform all steps in "Operational Checks Before Starting

Engine."
2. Set engine speed control lever slightly above "LOW
IDLE" (Figure 6).
3. Sound horn.

FG007557
Figure 6

" "
4. Turn starter switch to the (ON) position (Figure
7). When preheat cycle is completed, the preheat O I
indicator light (1, Figure 8) will turn "ON."

FG008069
Figure 7

FG007559
Figure 8

Operation OP000470
3-6
5. After the preheat completion, immediately turn starter

switch to " "

(START) position (Figure 9). Engine O I
should start in approximately five seconds.

WARNING!
If the engine does not start after approximately fifteen
seconds of cranking, release the starter switch. Wait
about five minutes and repeat above step. FG001372-1
Figure 9
6. After engine has started, release key. Key will return to the
"I" (ON) position (Figure 9).
7. 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.
8. Follow "Hydraulic System Warm-up" procedures in this
section. (See page 3-9)

Starting Engine With a Booster Cable

WARNING!
1. An explosive gas is produced while batteries are in
use or being charged. Keep flames or sparks away
from the battery area.
2. Charge batteries in a well ventilated area.
HAOA440L
3. Always wear eye protection when starting a machine
Figure 10
with jumper cables.
4. Improper jump starting procedures can cause an
explosion resulting in personal injury.
5. Jump start vehicles on dry ground or concrete. Do not
jump start the machine on a steel floor, because the
floor is always grounded.
6. When starting from another machine, make sure the
machines do not touch.
7. Always connect the auxiliary battery positive (+)
terminal too depleted battery positive (+) terminal first.
Then connect auxiliary battery negative (-) terminal to
the frame of the depleted battery machine second.
8. Connect positive cable first when installing cables and
disconnect the negative cable first when removing.

Operation OP000470
3-7
 IMPORTANT
The machine has a 12V (-) negative ground electrical
system. Use the same capacity 12V booster batteries when
jump starting engine.

If the batteries are drained during starting procedures, jump start

engine using auxiliary or booster batteries according to the
following procedure:

Connecting the Booster Battery

a
1. Shut down engine of the machine on which booster battery Red
is mounted (c, Figure 11).
2. Connect one end of red cable (a, Figure 11) to the
positive (+) terminal of the machine battery, and the c d
other end to the positive (+) terminal of the booster
battery (c, Figure 11).
3. Connect one end of black cable (b, Figure 11) to the Black
e
negative (-) terminal of the booster battery, and then b
make ground connection to the upper frame of the AXO0510L
machine (e, Figure 11) to be started with the other end Figure 11
of black (-) cable (b, Figure 11). When making the last
connection to upper frame, be sure to connect the
cable end as far away from the machine battery as
possible. DO NOT CONNECT DIRECTLY TO THE
NEGATIVE BATTERY TERMINAL.
4. Start the engine.

Disconnecting the Booster Battery

1. Disconnect black negative (-) cable (b, Figure 11) from
the machine frame first.
2. Disconnect the other end of black negative (-) cable (b,
Figure 11) from the booster battery.
3. Disconnect red positive (+) cable (a, Figure 11) from
the booster battery.
4. Disconnect red positive (+) cable (a, Figure 11) from
the machine battery.

Operation OP000470
3-8
Hydraulic System Warm-up

WARNING!
If a problem or abnormal operation occurs, immediately
shut down engine. Allow excavator to reach normal
operating temperature before starting work, especially in
cold weather.

The correct operating temperature of the hydraulic oil is 50° -

80°C (120° - 175°F). Make sure to follow the procedures listed
here for hydraulic fluid warm-up.
1. Run engine for approximately five minutes set at the middle
of the speed range, without a load.

FG007561
Figure 12

2. Set safety lever (1, Figure 13) on "UNLOCK" position.

Lock

Unlock

FG007562
Figure 13

3. Slowly cycle boom, arm and bucket cylinders about five

times without a load to circulate the oil through the system.
Do this for five minutes.
4. Check for clearance and fully raise the front attachment.
Swing clockwise 3 revolutions. Swing counterclockwise 3
revolutions.
5. Travel forward and reverse at low speed for two revolutions
of the drive sprocket.

FG007563
Figure 14

Operation OP000470
3-9
Hydraulic System Warm-up – Cold
Weather
1. Run engine at "LOW IDLE" (no load) for five minutes
(Figure 15).

FG007557
Figure 15

2. Run engine for approximately five minutes set at the middle

of the speed range, without a load (Figure 16).

FG007561
Figure 16

3. Set safety lever (1, Figure 17) on "UNLOCK" position.

Lock

Unlock

FG007562
Figure 17

4. Slowly cycle boom, arm and bucket cylinders about five

times without a load to circulate the oil through the system.
Do this for five minutes.

FG007563
Figure 18

Operation OP000470
3-10
5. Set engine speed control dial to "HIGH IDLE" (Figure
19).
6. 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.
7. Check for clearance and fully raise the front attachment.
Slowly swing clockwise 3 revolutions. Slowly swing
counterclockwise 3 revolutions.
8. Travel forward and reverse at low speed for two revolutions FG007564
of the drive sprocket. Figure 19

Engine Shut Down

NOTE: Allow engine to idle for three - five minutes before
shutting down the engine. If not allowed to idle, heat
surge may develop which will damage the engine.
Allowing the engine to idle will dissipate heat.
1. Park machine on firm, level ground.
2. Lower front end attachment to ground and make sure all
operating controls are in "NEUTRAL."

FG007565
Figure 20

3. Set safety lever on "LOCK" position (Figure 21).

Lock

Unlock

FG007566
Figure 21

4. Set engine speed control lever to "LOW IDLE" (Figure

22). Allow engine to idle for three - five minutes.

FG007557
Figure 22

Operation OP000470
3-11
5. Shut down engine by turning key to "O" (OFF) position
(Figure 23). O I
6. Remove key from starter switch.

FG001364
Figure 23

Check and Confirmation After Stopping

Engine
1. Repair excavator, if there are any coolant or oil leaks.
2. Inspect front attachment and under carriage for abnormal
appearances. Correct any problems.
3. Fill fuel tank.
4. Get rid of any accumulated flammable materials such as
leaves and paper etc. in engine compartment.
5. Clean all mud, etc. from undercarriage and tracks. Make
sure that all steps and hand holds are clean, and that the
operator's cabin is clean.
6. Check machine for loose parts

IMPORTANT
Place machine on level surface, lower bucket and
blade to ground, shut down engine and lock control
lever.

Walk around machine and check for loose parts. Retighten,

as necessary. For example, swivel bearing bolt should be
tightened to 112.8 Nm / 11.5 kg•m (83 ft lb). Figure 24

Operation OP000470
3-12
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"
position.

Be careful not to move the operation lever when raising up

or pushing down the safety lever. Lock
The safety lever is designed to lock the working control levers so
even if the working control levers are moved unintentionally, they Unlock
will not work. However, the safety lever does not control the
travel levers and boom swing pedal.
1. Pull safety lever up to allow left-hand control console to
raise into the "LOCKED" position. Make sure that the
safety lever is "LOCKED" into the raised (up) position.
When safety lever is in the "LOCKED" position, front
FG007566
attachment movement will be disabled even though a lever
Figure 25
is moved.
NOTE: Lower bucket (front attachment) and blade to
ground. Place all control levers in "NEUTRAL"
and shut down engine.
2. Set safety lever on "RELEASE/UNLOCK" position, by
pushing it down before starting work.
NOTE: When the engine is not running, but the safety
lever is "RELEASED" and the starter key is
tuned "ON," moving the joysticks may result in
movement. The charged accumulator in the
system will provide pilot pressure for control
valve spool movement.
NOTE: If the front attachment moves when the safety
lever is moved to the "RELEASE/UNLOCK"
position and all levers and pedals are in
"NEUTRAL," return the safety lever to "LOCK"
position, shut down engine and contact your
nearest DOOSAN dealer. There is a
malfunction with the system.
NOTE: If the pilot cutoff switch mounted on switch
panel is not pressed to "I" position when the
safety lever is in "RELEASE/UNLOCK" position,
the operator cannot operate the work levers
(Joysticks). (See page 2-20)

Operation OP000470
3-13
TRAVEL

WARNING!
1. 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). In this case,
the response of the travel levers will be the reverse of
normal operation.
2. Before moving, make sure that there are no personnel
in the way or on the machine. Sound the horn to alert
workers that you are about to move the machine.
3. Be sure the path is clear during travel.
4. Use extreme caution when reversing travel. Be sure
there is a clear path behind the machine.
5. Make sure to operate the travel control levers
smoothly to avoid sudden starts or stops.
6. Before leaving the operator's seat, make sure to lock
out all control systems and shut down the engine to
avoid accidental activation.

Travel Speed Control

WARNING!
Do not change the travel mode while traveling. Always use
speed mode "O" when traveling down a slope. It is very
dangerous to change to speed modes indicated "I" or "II"
while going down a slope. Only change travel mode after
coming to a complete stop.

Two travel speed ranges can be selected by using the travel

speed selector switch on the control panel (Figure 26).
"O" (LOW) - In this position low travel speed and a higher torque
are selected.
"I" (HIGH) - In this position high travel speed and a lower torque O
are selected.
I
HDO2022I
Figure 26

Operation OP000470
3-14
Travel Control Lever Operation
1. 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"
FG007567
Figure 27

2. Pivot turns (Figure 28) are made by rotating only one

track forward or backward. The machine will pivot on
the nonmoving track.
NOTE: "X" is the sprocket end of the track.

"X"
FG007568
Figure 28

3. Spin turns (Figure 29) are made by rotating one track

forward and one track backward. The machine will spin
around its center point, thus counterrotating.
NOTE: "X" is the sprocket end of the track.

"X"
FG007569
Figure 29

4. Stopping travel (Figure 30) - Returning travel levers to

"NEUTRAL" position will automatically apply brakes and
stop excavator.
NOTE: "X" is the sprocket end of the track.

"X"
FG007570
Figure 30

Operation OP000470
3-15
General Travel Instructions
1. Set engine speed control lever (Figure 31) on desired
speed.

FG007564
Figure 31

2. Set safety lever on "UNLOCK" position, and folding the

front, raise it 40 - 50 cm (16 - 20 in) above ground. Lock
See Figure 32.
Unlock

40 ~ 50 cm

FG007571
Figure 32

3. Raise dozer blade all the way up.

FG007658
Figure 33

4. When possible, travel on firm, level ground. Avoid sudden

movements and sharp turns.
5. When traveling on rough ground, travel at a slow speed
[1.0 - 1.5 km/h (0.62 - 0.93 MPH)]. Reduced engine speed,
to avoid shock loading the equipment. Be careful that an
excessive force is not added to equipment by touching or
climbing on rocks.
6. On rough, frozen or uneven terrain, travel slowly.

FG008062
Figure 34

Operation OP000470
3-16
 WARNING!
When traveling, keep bucket from 20 - 30 cm (8 - 12 in)
above ground. 20~
30 C
Do not travel backward on a slope. m

Never turn or travel crosswise on a slope.

Choose a safe alternate route before climbing a slope.
FG008060
FG007572
If excavator starts to slip or becomes unstable, lower
Figure 35
the bucket immediately into the ground, using it as a
brake.
Avoid working on slopes, because there is a danger of
overturning by becoming unbalance while swinging
and performing front attachment operations.
It is very dangerous to swing towards bottom of slope
with a loaded bucket.
In unavoidable cases level the slope with fill soil,
to make the vehicle as horizontal as possible. See
Figure 35.
Do not travel on slopes more than 30° due to turnover
danger. Figure 36

7. Travel straight up or down slopes, never diagonally across

the slope. See Figure 36 and Figure 37. Extend the
arm and lower the boom to keep the bucket about
20 - 30 cm (8 - 12 in) off the ground. If the machine
starts to slide or becomes unstable, lower the bucket to
regain control. If the engine stalls, lower the bucket,
make sure that all controls are in the neutral position
and restart the engine.
NOTE: Even though engine stops on a slope, do not
operate swing control. The hydraulic Cm
30
20~
accumulators may cause the unit to swing. FG007573
Figure 37
NOTE: Do not open or close operator's door on a slope.
Make sure door is latched.
8. If dirt or mud builds up in the track frame, raise each track
and rotate and clean that track.

CAUTION!
When using the boom and arm to lift any portion of the
machine, roll the bucket until the round base is against
the ground. The angle of the arm to the boom should
be at 90°.
FG007574
Figure 38

Operation OP000470
3-17
 Make sure that the material buildup has been cleared.
See Figure 38 and Figure 39.
9. The excavator can travel in water that comes up to center
of upper carriage rollers. Make sure that footing is solid so
the machine will not sink.
90 ~ 100
NOTE: If the machine is submerged to the point that
water or mud gets into the swing bearing or
center joint, stop machine operation. Remove
the machine from the submerged location to
firm, dry ground. Do not operate until proper
FG007575
inspection and maintenance have been
Figure 39
completed. Refer to the Shop Manual or contact
your distributor.

Operation OP000470
3-18
OPERATING INSTRUCTIONS

Engine Speed Control

Engine speed can be manually adjusted using the engine speed
control lever, Increase engine speed by pulling the lever back.
Decrease engine speed by pushing the lever forward.

IMPORTANT
The engine speed control system has been set at the
factory and should not require adjustment as part of routine FG007576
maintenance. Figure 40

Work Levers (Joysticks) (ISO Style)

1 5

3 4 7 8
WARNING!
9
2 6
Check surrounding area before swinging. When operating a
10
lever while in auto idle, do it carefully, because the engine
speed will increase rapidly.

NOTE: When starting work, move work levers (joysticks) FG007577

slowly and check movement of swing and front Figure 41
attachment.
This equipment is manufactured using the lever configuration
described in ISO standards. Do not change valving, hoses, etc.,
that would change this standard. The boom, arm and bucket
movements and swing direction of work levers (joysticks) are as
follows:

Left-hand Work Lever (Joystick) (Figure 41 and Figure

4
42)
3
1. Arm dump
1
2. Arm crowd
3. Left swing 2

4. 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 FG007578
down. Figure 42

Operation OP000470
3-19
NOTE: The following is not a mechanical malfunction but a
proper phenomenon of the excavator. When
operating the arm, it may stop momentarily. When the
arm is operated, the weight of the arm may cause it to
move faster than the amount of oil being supplied.

FG007579
Figure 43

Right-hand Work Lever (Joystick) (Figure 41 and Figure

44) 6
5. Boom down
6. Boom up
7. Bucket crowd 5

8. Bucket dump 7
8
NOTE: Even after stopping the engine, the front and the
dozer can be lowered to the ground by operating
work lever (joystick), by setting safety lever on FG007580
"UNLOCK" position and turning starter switch "ON." Figure 44

Right-hand Dozer Lever

9. Dozer down
10. Dozer up

10

9
FG007581
Figure 45

Operation OP000470
3-20
Change Machine Control Pattern by Select
Valve (If Equipped) 1 5

3 4 7 8

WARNING! 2 6

Check surrounding area before swinging. When operating a

lever while in auto idle, do it carefully, because the engine
speed will increase rapidly.
FG007624
Figure 46

NOTE: When starting work, move work levers (joysticks)

slowly and check movement of swing and front <ISO PATTERN>
attachment.
The machine control pattern can easily be changed to the ISO
standard or to the standard backhoe loader hydraulic system
(BHL) by changing the position of the select valve (if equipped). B BHL
Use the following procedure to change the position of the select
A
valve. ISO
The select valve is located in the rear of the cabin.
1. Rotating spool to the ISO position or to the BHL <BHL PATTERN>
position. (Figure 47)

B BHL

A
ISO
FG007582
Figure 47

Operation OP000470
3-21
Work Levers (Joysticks) (BHL Style)

Left-hand Work Lever (Joystick) (Figure 46 and Figure

4
48)
2
3
1. Boom down
2. Boom up
3. Left swing
4. Right swing 1

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 FG007583
down. Figure 48

Right-hand Work Lever (Joystick) (Figure 46 and Figure

49)
5. Arm dump
5
6. Arm crowd
6
7. Bucket crowd
7
8. Bucket dump
8
NOTE: The following is not a mechanical malfunction but a
proper phenomenon of the excavator. When
operating the arm, it may stop momentarily. When the FG007584
arm is operated, the weight of the arm may cause it to Figure 49
move faster than the amount of oil being supplied.
NOTE: Even after stopping the engine, the front can be
lowered to the ground by operating work lever
(joystick), by setting safety lever on "UNLOCK"
position and turning starter switch "ON."

FG007579
Figure 50

Operation OP000470
3-22
OPERATING PRECAUTIONS

WARNING!
Do not rest your feet on the travel pedals during normal
machine operation. Unexpected machine travel may occur
in this situation.

1. Before starting work, investigate terrain and soil condition.

Level ground and drain area if necessary.
2. Install window guards when working where there is a
possibility of falling rocks or other objects.

FG007586
Figure 51

3. Check strength of supported structures in advance before

working on them. If insufficient, reinforce it. If any doubt
exists about structural strength, refuse to operate unit.
4. It is possible that the boom, arm or bucket may come into
contact with the upper or lower structure of the machine.
There are digging conditions which could allow this to
happen.

FG007588
Figure 52

5. Do not continually "bottom out" the hydraulic cylinders.

Machine damage may occur if the cylinders are fully
extended or retracted, example: arm cylinder fully retracted
and the bucket cylinder is extended to rotate the bucket
into the ground.

FG007589
Figure 53

Operation OP000470
3-23
6. Do not use machine travel or swing when the bucket is
in the ground to provide additional breakout force. See
Figure 54.

FG007590
Figure 54

7. Do not use machine weight to provide additional breakout

force. See Figure 55.
8. When working on soft or muddy ground, make sure that
the machine is not sinking.

FG007591
Figure 55

9. When working close to the excavated edge, make sure that

the ground the machine is sitting on is solid. Keep the
travel motors (1, Figure 56) to the rear. See Figure 56.

FG007592
Figure 56

10. Do not excavate underneath the machine. See Figure

57.

FG007593
Figure 57

Operation OP000470
3-24
11. Make sure that there is adequate clearance from overhead
electrical supply lines. See Figure 58.

FG007594
Figure 58

12. If the excavation is in an underground location or in a

building, make sure that there is adequate overhead
clearance and that there is adequate ventilation. See
Figure 59.

FG007595
Figure 59

13. Do not use the bucket as a hammer or ramming device.

This is dangerous and causes damage to the front
attachment. See Figure 60.

FG007596
Figure 60

14. Do not dig with the excavator tracks raised. This can result
in structural and mechanical failures.

FG007627
Figure 61

Operation OP000470
3-25
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. Return levers to neutral by hand.
Do not let them snap back to neutral on their own.
16. If the optional long fronts or attachments or heavy duty
FG007597
front end attachments are used, the machine balance will
be altered. Follow these additional operating precautions. Figure 62

WARNING!
Do not travel downhill with the front end attachments
raised.
Do not travel across slopes; travel straight up or down
slope.
Use extreme caution when swinging the upper frame
when positioned on a slope.
Allow extra swing stopping room. The additional
momentum generated by the longer or heavier front
end equipment will increase the amount of time
needed to stop the swing motion.
Make sure that all optional equipment has been
authorized and installed properly.

17. Do not move dirt or objects by swinging the excavator into

them. This can result in structural and mechanical failures.

Operation under Water or on Weak Ground

1. If a riverbed is uneven or the current is swift, be especially
careful. Do not travel in water deeper than the upper part of
the shoes on the idler end of tracks. Be careful not to
submerge the center joint, swivel bearing or pinion gear in
water, mud or sand.
2. On weak, unstable surfaces, the machine may sink: keep
watching the tracks and checking the riverbed surface.

FG007628
IMPORTANT Figure 63

If the center joint, Swivel bearing or pinion gear are

submerged in water, mud or sand, they need to be
serviced, either lubricated or in some cases rebuilt.
In addition, any other component that is
submerged, such as a bucket pin, should be
lubricated.

Operation OP000470
3-26
PARKING EXCAVATOR

WARNING!
Park machine on firm, level ground. Avoid parking on 120
slopes. If excavator must be parked on a slope, block tracks
and place bucket teeth in ground. See Figure 64.

FG007608
Figure 64

1. Park machine on firm, level ground. Lower bucket to

ground as shown in Figure 65.

FG007609
Figure 65

2. Set engine speed control dial on "LOW IDLE."

FG007557
Figure 66

3. If you touch the operation lever unintentionally, it may

create a serious accident. Before leaving operator's seat, Lock
set safety lever on "LOCK" position.
Unlock

FG007566
Figure 67

Operation OP000470
3-27
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.
Attach chain or wire rope to track frame as shown in
Figure 68
Insert protective material such as thick cloths between
Shackle
track frame and wire rope to prevent the wire rope from
being damage.

Towing Wire FG000669

IMPORTANT Figure 68

Use shackle hook on track frame to only haul objects that

weigh less than 5 metric tons (5.51 U.S. Tons). Never use it
to haul objects over 5 metric tons (5.51 U.S. Tons).

Operation OP000470
3-28
HYDRAULIC BREAKER

IMPORTANT
If a hydraulic breaker and piping is installed without
DOOSAN's authorization, it may create a serious
malfunction which will not be covered under the excavator
warranty.

Selection of 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

1. When installing hydraulic breaker, assemble according to
drawings provided with kit.
2. If breaker is taken off excavator, be sure to plug and cap all
hoses and tubing to prevent contamination from entering
hydraulic system.
3. Plug and cap all connectors and fittings on breaker to
prevent contamination.
4. Check all hydraulic connections for signs of leaks or loose
components before starting operation.

Operation OP000470
3-29
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.
1. Make sure to read and understand the breaker user's
manual.
2. Inspect all mechanical and hydraulic connections.
3. Do not use the breaker as a hammer. See Figure 69.
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.

FG007610
Figure 69

4. Do not operate the breaker with the boom or arm cylinders

fully extended (bottomed out). See Figure 70.
Leave over 100 mm (4 in) of clearance between rod end of
cylinder and cylinder head. This will help prevent damage
to cylinders during breaker operation.

FG007611
Figure 70

5. Do not use the breaker if the hydraulic hoses vibrate

excessively. See Figure 71. Check the breaker's 1
hydraulic accumulator (1) for damage and repair as
required. If excavator is operated under this condition,
structural and hydraulic components can be damaged.

FG007612
Figure 71

Operation OP000470
3-30
6. Do not allow the breaker body to go into water if not
equipped for underwater operation. The breaker seal can
be damaged and allow rust, foreign material or water to
enter the hydraulic system and cause damage. Only insert
the breaker tool into water. See Figure 72.

FG007613
Figure 72

7. Do not any lifting or towing with a breaker. See Figure

73.

FG007614
Figure 73

8. Operate the breaker only to the front and rear of the

excavator. Do not use the breaker to either side of the
excavator. Do not swing the breaker from side to side when
operating it. See Figure 74.

WARNING!
Operating a breaker with the upper body turned 90° to
the tracks can result in tipping over the machine or
reduction in service life. FG007615
Figure 74

9. Do not curl the breaker tool tip into the arm or boom when
traveling or parking the excavator. See Figure 75.

FG007616
Figure 75

Operation OP000470
3-31
Hydraulic Oil and Filter Service Intervals
When using a hydraulic breaker, the viscosity breakdown and
contamination of hydraulic oil is faster because the work
condition is more severe than during normal digging work. To
prevent the hydraulic components (especially pump) from
having a shortened life cycle, replace the hydraulic oil and main
hydraulic oil return filter using the following schedule.

Attachment Operation Rate Hydraulic Oil Filter

250 Hours (First Replacement)
Bucket Work 100% 2,000 Hours
1,000 Hours (After First Replacement)
Hydraulic Breaker
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.

100

105 551

106 110 614

80
BREAKER OPTION RATE (%)

112 130 FILTER 692

(First Replacement)
119 150 782
60

128 180 893

HYDRAULIC OIL
137 210 1028
40
FILTER
156 250 (After First Replacement) 1196

175 300 1400

20

206 3705 1658

0 500 1000 1500 2000

MACHINE OPERATING HOURS

FG007618
Figure 76

NOTE: The replacement intervals of hydraulic oil and filter

depend upon the amount of time the hydraulic
breaker is being used. These intervals should be
followed as opposed to regularly scheduled
maintenance.

Operation OP000470
3-32
PTO Pedal Valve (Optional)

Rotating Attachment Using the Pedal Valve

1. Pressing end (1, Figure 77) of pedal, is used to turn 1
clockwise.
4
2. Pressing end (2, Figure 77) of pedal, is used to turn
counterclockwise. 2
NOTE: Before activating the pedal, be sure to check 3
the function of the attachment. FG007599
Figure 77
Breaker Operation Using the Pedal Valve
1. Pushing down on the top end of the PTO pedal, operates
the breaker.
2. Releasing the pedal stops the breaker.

Locking the Pedal

When rotating is not needed, the pedal can be locked by using
the prop rod (3) locking device.
Locking is completed when the top end of the prop (3) is
positioned into pedal hole.

FG007600
Figure 78

A. Position for "UNLOCKING."

B, Position for "LOCKING."
B

FG007601
Figure 79

Operation OP000470
3-33
Boom Swing Pedal
This pedal, located near the operator's right foot swings the
boom. The pedal is used to dig along a gully wall or a retaining
wall.

How to operate boom

Pressing the left of the pedal (1, Figure 80) swings the
boom to the left, while pressing the right of the pedal (2,
3
Figure 80) swings the boom to the right.
When boom swing pedal is not in use, lock pedal lock by moving
it from position (3, Figure 80) to (4, Figure 80). When
4
unlocking it, move it from position (4, Figure 80) to (3,
Figure 80). 2
1
FG007602
Figure 80

1. Left swing: 70°

2. Right swing: 50° 1 2
50
70

FG000382

FG007585
Figure 81

Blade Control Lever

The blade control lever, located on the right-hand side of the
driver's seat, controls the operation of the blade. When the lever
is released, it goes to the NEUTRAL position and the blade
stops immediately. 1
1. Pulling lever back "RAISES" dozer blade.
2. Pushing lever forward "LOWERS" dozer blade. 2

FG007603
Figure 82

Operation OP000470
3-34
 Figure 83

Precautions for Blade Use

The blade control lever, located on the right-hand side of the
driver's seat, controls the operation of the blade. When the lever
is released, it goes to the NEUTRAL position and the blade
stops immediately.
1. Use the blade only for earth moving. Do not use the blade
to dig: this can damage the blade or the track system.
2. Do not apply a large or unbalanced, off-center load to the
blade: this can damage the blade or the track system.
3. Do not strike anything with the blade while traveling. This
can damage the blade or track system.
4. When using the blade to jack up the machine, make sure
the ground is even and will give good support and that the
blade contacts the ground evenly.
5. When the blade is positioned in front of the machine, while
excavating or bringing the front attachment in, be careful
not to strike and damage the blade.

Operation OP000470
3-35
OPERATING TECHNIQUES

Lifting

IMPORTANT
There may be local or government regulations, about the
use of excavators for the lifting of heavy loads. Always
contact your local and government agencies in regards to
these regulations.

Lifting Unknown Weight

When loads are not accurately known are to be lifted, the person
responsible for the job shall ascertain that the weight of the load FRONT LIFT
ZONE
does not exceed the machine LOAD RATING CHART at the
radius at which it is to be lifted.
It is recommended that you feel your way into any lift as a
precaution against tip-over. One method is to position the boom
at 90° over the side of the machine. Slowly lift the load until it SIDE LIFT SIDE LIFT
clears the ground. A lift over the side is the most unstable, and ZONE ZONE
as the load is swung into the front zone of the excavator it will
become more stable. DO NOT INCREASE SWING RADIUS
AFTER THE LOAD IS LIFTED.
REAR LIFT
ZONE
DANGER! FG007617
Figure 84
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. 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.
We recommend when traveling with a suspended payload, you
evaluate the prevailing conditions and determine the safety
precautions required in each case. The following factors must be
considered before attempting to pick and carry a load.

Operation OP000470
3-36
Align the boom with the forward direction of machine travel.
Maintain this boom position when turning the machine. Turn only
when necessary, at the slowest speed, and at a wide turning
radius.
1. Use the shortest lifting radius distance possible.
2. Keep the load as close to the ground as conditions will
permit.
3. Provide tag lines to prevent load from pendulating.
Pendulating can cause a change in radius. A change in
radius could exceed the load chart rating or cause a
tip-over condition.
4. Govern travel speed to suit conditions.
5. Avoid sudden starts and stops.

Operation OP000470
3-37
OPERATION UNDER UNUSUAL
CONDITIONS
NOTE: See “Long Term Storage” on page 4-55 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.
1. Check the cooling system for correct antifreeze solution for
lowest temperature expected. Carefully inspect cooling
system and correct or report any leaks.
2. Keep batteries fully charged to prevent freezing. If water is
added to batteries, run engine at least one hour to mix
electrolyte solution.
3. Keep engine in best possible mechanical condition to
assure easy starting and good performance during
adverse weather.
4. Use engine oil of the proper specifications for the expected
temperatures. Refer to the "Lubrication Specifications" of
the engine manual for details.
5. Keep fuel tank full at all times. Drain condensation from
tank before and after operation. Drain and service fuel
filter. To eliminate clogging of fuel filters due to wax crystal
formation in the fuel, be sure that the fuel used has a cloud
point specification below the lowest expected temperature.
6. Lubricate entire machine according to "Periodic Service
Table and Chart" Section 4, in this manual or lubrication
chart on machine.
7. Start engine and allow it to reach normal operating
temperature before applying load.
A. If mud and ice collects and freezes on any of the
moving parts while machine is idle, apply heat to
thaw the frozen material before attempting to operate
machine.
B. Operate hydraulic units with care until they have
reached a temperature to enable them to operate
normally.
C. Check all machine controls and/or functions to be
sure they are operating correctly.
8. An extra outer air filter should be kept in the operator's
cabin to replace element that could become iced and
cause restricted airflow to engine.

Operation OP000470
3-38
9. If cold weather starting aid must be used, see "Engine
Starting" COLD WEATHER START portion of this manual.
10. Clean off all mud, snow and ice to prevent freezing. Cover
machine with tarpaulin if possible, keep ends of tarpaulin
from freezing to ground.

Operation in Extreme Heat

Continuous operation of the machine in high temperatures may
cause the machine to overheat. Monitor engine and
transmission temperatures and stop machine for a cooling-off
period whenever necessary.
1. Make frequent inspections and services of the fan and
radiator. Check coolant level in radiator. Check grills and
radiator fins for accumulation of dust, sand and insects
which could block the cooling passages.
A. Formation of scale and rust in cooling system occurs
more rapidly in extremely high temperatures. Change
antifreeze each year to keep corrosion inhibitor at full
strength.
B. If necessary, flush cooling system periodically to keep
passage clear. Avoid use of water with a high alkali
content which increases scale and rust formation.
2. Check level of battery electrolyte daily. Keep electrolyte
above plates preventing damage to batteries. Use a slightly
weaker electrolyte solution in hot climates. Dilute 1.28
specific gravity electrolyte as issued to 1.20 - 1.24 specific
gravity readings at full charge. Recharge batteries
whenever they reach a 1.16 specific gravity reading.
Batteries self-discharge at a higher rate if left standing for
long periods at high temperatures. If machine is to stand
for several days, remove batteries and store in a cool
place.

WARNING!
Do not store acid type storage batteries near stacks of
tires; the acid fumes have a harmful affect on rubber.

3. Service fuel system as directed in "Engine Fuel System"

Section 5, of this manual. Check for water content before
filling fuel tank. High temperatures and cooling off cause
condensation in storage drums.
4. Lubricate as specified in "Periodic Service Chart and
Table" Section 4, in this manual or Lubrication Decal on the
machine.
5. Do not park machine in sun for long periods of time. When
practical park machine under cover to protect it from sun,
dirt and dust.

Operation OP000470
3-39
 A. Cover inactive machine with tarpaulin if no suitable
shelter is available. Protect engine compartment,
transmission and hydraulics from entrance of dust.
B. 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.
C. Protect all unfinished, exposed surfaces with a film of
preservative lubricating oil. Protect cables and
terminals with ignition insulation compound. Apply
paint or suitable rust preventive to damaged surfaces
to protect them from rust and corrosion.

Operation in Dusty or Sandy Areas

Operation of the machine can cause dust in almost any area.
However, when in predominantly dusty or sandy areas,
additional precautions must be taken.
1. Keep cooling system fins and cooling areas clean. Blow
out with compressed air, if possible, as often as necessary.

WARNING!
Wear goggles when using compressed air.

2. Use care when servicing fuel system to prevent dust and

sand from entering the tank.
3. Service the air cleaner at frequent intervals, check air
restriction indicator daily and keep dust cup and dust valve
clean. Prevent dust and sand from entering engine parts
and compartments as much as possible.
4. Lubricate and perform services outlined on current
lubrication chart on machine and "Lubrication Chart and
Table" Section 4. Clean all lubrication fittings before
applying lubricant. Sand mixed with lubricant becomes
very abrasive and speeds wear on parts.
5. Protect machine from dust and sand as much as possible.
Park machine under cover or protect with tarpaulin to keep
dust and sand from damaging unit.

Operation OP000470
3-40
Operation in Rainy or Humid Conditions
Operation under rainy conditions is similar to that as in extreme
heat procedures listed previously.
1. Keep all exposed surfaces coated with preservative
lubricating oil. Pay particular attention to damaged or
unpainted surfaces. Cover all paint cracks and chip marks
as soon as possible to prevent corrosive effects.

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.
1. When exposed to salt water, dry machine thoroughly and
rinse with fresh water as soon as possible.
2. Keep all exposed surfaces coated with preservative
lubricating oil. Pay particular attention to damaged paint
surfaces.
3. Keep all painted surfaces in good repair.
4. Lubricate machine as prescribed on lubrication chart on
machine or "Periodic Service Table and Chart" Section 4,
in this manual. Shorten lubricating intervals for parts
subject to exposure to salt water, if found necessary.

Operation at High Altitudes

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

Operation OP000470
3-41
Operation OP000470
3-42
 OP000471

4Inspection, 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. The service cycles may need to be
shortened depending on the working conditions.
Extremely hot or dusty conditions will require more
frequent service. Operational hours are determined
by the amount of time accumulated on the engine
hour meter on the control console in the cabin. HAOA601L
Figure 1

Product Identification Number (P. I. N.)

Location
A P.I.N. number, is stamped on the main frame, under the
boom foot (Figure 2). It is also stamped on the product
identification plate (Figure 3) on outside of the cabin in front.
NOTE: Please make note of these numbers and their
locations. These will be required whenever warranty
or service work is requested. Keep this number on
file, incase the machine is stolen.
FG007645
Figure 2

Inspection, Maintenance and Adjustment OP000471

4-1
 7-11, Hwasu-dong, Dong-gu,
Incheon, Korea

K1011647A

FG007656
Figure 3

Component Serial Numbers

There are many serial numbers on each traceable
component of the machine. For example, the engine serial
number is stamped on the rear left side of the engine block,
above the starter. Additional engine information is described
on a label (Figure 4) on the rocker cover.
Please make note of these numbers and their locations.
These will be required whenever warranty service work is
requested.
FG007659
Figure 4

Safety Precautions
1. Make sure to lock out the hydraulic controls and post a
notice (Warning Tag) that the machine is being
serviced to prevent any unauthorized operation.
2. Make sure to clean up any fluid spills, especially
around the engine.
3. Inspect all fuel lines to make sure that fittings, lines,
filters and O-rings, etc., are tight and are not showing
signs of wear or damage.
4. If the inspection or test procedure requires that the
engine be running, make sure to keep all unauthorized
personnel away from the machine, and that all industry
standard safety precautions are followed.

Inspection, Maintenance and Adjustment OP000471

4-2
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.
1. Park on firm, level ground.
2. Lower bucket to ground.

FG007565
Figure 5

3. Set safety lever on "LOCK" position.

Lock

Unlock

FG007566
Figure 6

4. Allow engine to run at low idle for a minimum of five

minutes to allow engine to cool. If this is not done,
heat surge may occur.

FG007557
Figure 7

Inspection, Maintenance and Adjustment OP000471

4-3
5. Shut down engine by turning key to "O" (OFF) position.
Remove key from starter switch. O I

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.
FG001364
Figure 8

6. Before starting maintenance work, hang up a tag, "Do

Not Touch When Performing Inspection or
Maintenance" on cabin door or work lever.

Inspection or
Maintenance

FG007660
Figure 9

Inspection, Maintenance and Adjustment OP000471

4-4
TABLE OF RECOMMENDED
LUBRICANTS
NOTE: Refer to the Maintenance Intervals Table for
application points.

Ambient Temperature
Kind of -22 -4 14 32 50 68 86 104 122
Reservoir
Fluid °F
-30 -20 -10 0 10 20 30 40 50 °C

SAE 10W-30

Engine Oil **
* SAE 10W-40
Pan Engine Oil

SAE 15W-40

Swing Drive SAE 90 and API GL5

Case

Gear Oil * SAE 80W-90 and API GL5

Final Drive
Case SAE 140 and API GL5

ISO VG 32
***
Hydraulic
Hydraulic * ISO VG 46
Oil Tank
Oil
ISO VG 68

* ASTM D975 No. 2

Diesel
Fuel Tank
Fuel ASTM D975 No.
1

Grease
Grease * Multipurpose Lithium Grease NLGI No. 2
Fitting

Cooling Add Antifreeze

Coolant
System * (50% antifreeze - 50% distilled water)
* Installed at factory.
** Engine oil must meet ACEA-E5 or API-CI-4.

Inspection, Maintenance and Adjustment OP000471

4-5
 *** Hydraulic oil change interval is 2,000 hours, only when DOOSAN Genuine Oil is used. If other
brands of oil is used, guaranteed change interval is 1,000 hours.
API: American Petroleum Institute.
ACEA: Association des Constructeurs Europens d'Automobiles.
ASTM: American Society of Testing and Material.
ISO: International Standardization Organization.
NLGI: National Lubricating Grease Institute.
SAE: Society of Automotive Engineers.

IMPORTANT
Do not mix oils from different manufacturers. DOOSAN
does not endorse specific brands but does suggest that
owners select quality oils whose suppliers provide
assurance that required standards will always be met or
exceeded.
Fluctuating daily or weekly extremes of temperature, or
operation in subzero freezing weather may make it
impractical to use straight weight lubricants. Use good
judgment in selecting lubricant types that are
appropriate for climate conditions.

Inspection, Maintenance and Adjustment OP000471

4-6
FLUID CAPACITIES
Component Capacity
Engine Oil Pan with Filter 6.3 liters
(1.66 U.S. gal.)
Cooling System 2 liters
(0.5 U.S. gal.)
Fuel Tank 42 liters
(11.1 U.S. gal.)
Hydraulic Oil Tank Level 40 liters
(10.6 U.S. gal.)
System 60 liters
(15.9 U.S. gal.)
Travel Reduction Device (Each) 0.5 liters
(1.8 U.S. gal.)

LUBRICATION AND SERVICE

CHART
Lubrication and service chart is on the inside of battery box
cover. The symbols shown here are used in the lubrication
and service chart on the next page.

Symbol Description Symbol Description

Lubrication Coolant

Gear Oil (Swing Device, Travel

Air Cleaner Element
Device)

Engine Oil Fuel Filter

Engine Oil Filter Air Conditioner Filter

Hydraulic Oil Drain Water

Hydraulic Oil Return Filter

Inspection, Maintenance and Adjustment OP000471

4-7
Description of Lubrication and Service Chart

3 3 4 5 9 8 12,14

2
7

2 10

11

10h 13
2 50h
250h
500h
1000h
2000h

2 6
FG007707
Figure 10

Inspection, Maintenance and Adjustment OP000471

4-8
 SERVICE DATA
Service Interval
No. Items to Check Service Qty.
10 50 250 500 1000 2000
Coolant
1 Radiator 2 L V
(Antifreeze)
Front & Blade
2 Grease 17 F100 W10
(Note)
Boom Swing
3 Grease 4 F100
Cylinder (Note)
4 Swing Gear (Note) Grease 1
Swing Bearing
5 Grease 1 W10
(Note)
Travel Reduction Gear Oil
6 0.5 L V, F
Device (80W90)
Engine Oil
7 Engine Oil 6.3 L V F
(10W40)
8 Hydraulic Oil Tank Hydraulic Oil 40 L V
Fuel Tank Diesel 42 L V
9
Water Separator (Water-Drain) 1 V
10 Engine Oil Filter Cartridge 1 F
11 Fuel Filter Cartridge 1
Hydraulic Oil
12 Element 1 F
Return Filter
Air Cleaner (Outer) Element 1 C
13
Air Cleaner (Inner) Element 1
Hydraulic Oil
14 Element 1 F
Suction Strainer
V: Maintenance and Refill.
C: Cleaning.
F: First Time Exchange Only.
F100: Every 10 Hours For First 100 Hours.
W10: Every 10 Hours If Operating In Water.
: Replacement On Every Interval.
NOTE: Grease every 10 hours for first 100 hours.
Maintenance required when operating in water or mud.

Inspection, Maintenance and Adjustment OP000471

4-9
MAINTENANCE INTERVALS
SERVICE ITEM PAGE
10 Hour / Daily Service
Grease Dozer, Boom Swing and Front Attachment Pins (for first 100 hours) 4-12
Check Engine Oil Level 4-12
Check Level of Hydraulic Oil Tank 4-13
Check for Leaks in Hydraulic System 4-14
Check Fuel Level 4-15
Check for Leaks in Fuel System 4-15
Check Water Separator and Drain Water as Required 4-16
Check Cooling System and Refill As Required 4-16
Check Level of Window Washer Liquid 4-17
Inspect Cooling Fan Blade 4-17
Check Air Intake System 4-18
Inspect Seat Belt for Proper Operation 4-18
Inspect the Structure for Cracks and Faulty Welds 4-18
Check the Operation of All Switches 4-18
Check the Operation of All Exterior Lights, Horn and Monitor Lights 4-19
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at 4-19
Normal Operating Temperature. Listen for Any Abnormal Sounds
Check Operation of All Controls 4-19
50 Hour / Weekly Service
Perform All Daily Service Checks 4-20
Grease Front Attachment Pins 4-20
Grease Dozer Pins and Dozer Cylinder 4-21
Grease Boom Swing Cylinder and Bracket 4-21
Grease Swing Gear Pinion Teeth 4-21
Grease Swing Bearing 4-21
Drain Water and Sediment from Fuel Tank 4-22
Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours) 4-22
Change Engine Oil and Filter (After First 50 Hours) 4-22
Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts 4-22
(Links, Shoes, Rollers, Idlers)
250 Hour / Monthly Service
Perform All Daily and 50 Hour Service Checks 4-23
Clean Outer Filter of Air Cleaner 4-23
Change Engine Oil and Filter 4-24
Check Engine Fan Belt Tension 4-25
Check Engine Fan Belt Wear 4-26
Check Oil Level in Travel Reduction Device (One on Each Side of Unit) 4-27
Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 250 4-27
Hours)
Replace Hydraulic Oil Return Filter (After First 250 Hours) 4-27
Replace Hydraulic Oil Suction Filter (After First 250 Hours) 4-28

Inspection, Maintenance and Adjustment OP000471

4-10
 SERVICE ITEM PAGE
Inspect Pins and Bushings of the Front End Attachments for Signs of Wear 4-28
Check Fluid Levels in Batteries and Battery Charge Levels 4-28
Inspect for Any Loose or Missing Nuts and Bolts 4-28
Inspect Fuel System Hose Clamps 4-28
500 Hour / 3 Month Service
Perform All Daily, 50 and 250 Hour Service Checks 4-29
Replace Outer and Inner Air Cleaner Elements 4-29
Change Fuel Filter 4-30
1,000 Hour / 6 Month service
Perform All Daily, 50, 250 and 500 Hour Service Checks 4-31
Replace Hydraulic Oil Return Filter 4-31
Change Oil in Travel Reduction Device (One on Each Side of Unit) 4-32
Replace Hydraulic Oil Suction Filter 4-32
2,000 Hour / Yearly Service
Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks 4-33
Change Radiator Coolant 4-33
Hydraulic Oil Exchange and Suction Filter Replacing 4-34
Check Alternator and Starter** 4-35
Check All Rubber Antivibration Shock Mounts 4-35
Perform and Record the Results of the Cycle Time Tests 4-36
Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage 4-36
Check, Adjust Valve Clearance ** 4-36
Check Head Bolt Torques 4-36
4,000 Hour / Biennial Service
Major Parts - Periodic Replacement 4-37
12,000 Hour / Six Year Service
Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) 4-38

** These checks need to be completed by an authorized DOOSAN dealer.

Inspection, Maintenance and Adjustment OP000471

4-11
10 HOUR / DAILY SERVICE

Grease Dozer, Boom Swing and Front

Attachment Pins (for first 100 hours)

WARNING!
Do not remove the grease fitting until the pressure is
entirely bleed off by loosening grease fitting slowly to
avoid fatal wound.
FG000500
Let anybody never be in the blowing direction.
Figure 11
Be careful to any kinds of works for nipples and
hydraulic line plugs.

Grease every 10 hours for first 100 hours and every 50

hours thereafter (See page 4-21).
NOTE: If the unit has been running or working in water the
front attachment should be greased on a 10 hour /
daily basis.

Check Engine Oil Level 1

WARNING!
Allow the engine to cool before checking the oil level to 2
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.
FG007661
1. Shut down engine and wait for fifteen minutes. This will Figure 12
allow all oil to drain back to oil pan.
2. Remove dipstick (1, Figure 12) and wipe the oil off
with a clean cloth.
3. Insert dipstick fully in the oil gauge tube, then take it
out again.

Inspection, Maintenance and Adjustment OP000471

4-12
4. Engine oil level must be between "HIGH" and "LOW"
marks on dipstick. H

NOTE: If oil is above "HIGH" mark on dipstick, some

must be drained to return oil to proper level. L
5. Add oil through engine oil fill cap (2, Figure 12), if the
oil level is below the "LOW" mark.

FG000616
Figure 13

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. After the ARO1760L
pressure has been released, it is safe to remove either Figure 14
the fill cap or service covers.

1. Park machine on firm, level ground. Lower boom and

position bucket on ground as shown in Figure 15.
2. Set engine speed to "LOW IDLE."

FG007662
Figure 15

3. Set safety lever to "LOCK" position.

4. Check level gauge by opening right access door. Oil H
level must be between marks on sight gauge.
L

FG007663
Figure 16

Inspection, Maintenance and Adjustment OP000471

4-13
5. If the level is below "L" mark add oil.
A. Shut down engine.
B. The hydraulic tank is pressurized. Turn the
breather cap slowly to allow the pressurized air to
vent.
C. Remove the upper cover of the hydraulic tank and
add oil.

IMPORTANT FG007664
Figure 17
Do not fill above "H" mark on sight gauge.
Overfilling can result in damage to equipment and
oil leaking from hydraulic tank due to expansion.

6. If oil level is above the "H" mark drain oil.

A. Swing upper structure perpendicular (90°) to
tracks as shown in (Figure 18).
B. Shut down engine and wait for the hydraulic oil to
cool down.
C. Remove the right bottom cover.
D. Drain the excess oil from drain valve at the
bottom of the tank into a suitable container.
FG007690
Figure 18

Check for Leaks in Hydraulic System

1. Perform a daily walk-around inspection to make sure
that the hoses, piping, fittings, cylinders and hydraulic
motors are not showing any signs of leakage. If any is
noted, determine the source of the leak and repair.

Inspection, Maintenance and Adjustment OP000471

4-14
Check Fuel Level

2
WARNING!
Use extreme safety precautions while refueling to
prevent explosions or fire.
Immediately clean up any split fuel. 1

1. At end of each workday, fill fuel tank. Add fuel through FG007666
fuel fill tube (1, Figure 19). When working at a Figure 19
temperature of 0°C (32°F) or higher, use ASTM No.
2-D or its equivalent. At temperatures below 0°C (32°F)
use ASTM No. 1-D or its equivalent.
2. Make sure that the fuel fill hose is grounded to the
excavator before fueling begins.
3. Check the amount of fuel in the tank by observing the
fuel tank sight gauge (2, Figure 19).
NOTE: See “Fluid Capacities” on page 4-7. for
capacity.
4. The excavator may be equipped with the optional
battery operated fuel fill pump. The pump assembly is
in the hydraulic pump compartment. Put the suction
hose of the pump into the fuel resupply tank. Turn the
switch in the pump compartment "ON," and the fuel will
be pumped into the excavator fuel tank.
NOTE: See “Handling of Accumulator” on page 4-54,
for further information.
5. Do not overfill the tank.
6. Securely tighten cap after fueling.
NOTE: If breather holes (3, Figure 20) in cap are
clogged, a vacuum may form in the tank
preventing proper fuel flow to engine. Keep 3
holes in fuel cap clean.

FG000317
Figure 20

Check for Leaks in Fuel System

1. 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.

Inspection, Maintenance and Adjustment OP000471

4-15
Check Water Separator and Drain Water
as Required
1. A fuel water separator is inside the hood cover.
2. Open the access hood cover the on rear of the close
machine.
open
1. Open engine cover and check water separator.
2. When there is water in the cup, a red indicator will
appear in the float window.
FG007667
Figure 21

3. Turn lever to "CLOSED" position to shut off fuel supply

before draining water.
NOTE: Lever must be pointing up.
4. Remove ring nut (1, Figure 22), cup (2), separator (3)
and seals (4) from head (5).
5. Drain water and sediment from cup (2, Figure 22).
Wipe inside of cup out and clean separator (3).
NOTE: Dispose of drained fluids according to local
regulations.
6. Install seals (4, Figure 22), separator (3), cup (2) and Figure 22
ring nut (1) on head (5).
7. Turn fuel lever to "OPEN" position.
NOTE: Lever must be pointing down.

Check Cooling System and Refill As

Required

WARNING!
Allow the engine to cool before releasing the radiator
cap. Make sure to loosen the cap slowly to release any
remaining pressure.
Radiator cleaning is performed while the engine is
running. Take extreme caution when working on or near
a running engine. Make sure to lock out and tag the
controls notifying personnel that service work is being
performed.
Do not remove the radiator cap unless it is required.
Observe the coolant level in the coolant recovery tank.

NOTE: Do not mix ethylene glycol and propylene glycol

antifreeze together. If the two are mixed, the
protection level will be reduced to the level of the
ethylene glycol.

Inspection, Maintenance and Adjustment OP000471

4-16
1. When the engine is cold, remove the radiator cap and
check the coolant level inside the radiator. Do not rely
on the level of coolant in the coolant recovery tank.
Refill radiator as required. Refer to coolant
concentration table. (See page 4-53)
2. Check to make sure that the coolant transfer line from
FULL
the coolant recovery tank to the radiator is free and
clear of obstructions, or not pinched.
LOW
3. Observe the level of coolant in the coolant recovery
tank. The normal cold engine fluid level should be
FG007668
between "FULL" and "LOW" marks on tank.
Figure 23
4. If the coolant is below the "LOW" mark, add coolant to
this tank.

Check Level of Window Washer Liquid

1. Open the back hood door and the right door.
2. Check fluid level in windshield washer tank.
3. Open fill cap and add fluid.
NOTE: Use a washer liquid that is rated for all seasons.
This will prevent freezing during cold weather
operation. Use standard window cleaning fluid:
SSK703

FG008149
Figure 24

Inspect Cooling Fan Blade

WARNING!
Personal injury can result from a fan blade failure.
Never pull or pry on the fan. This can damage the fan
blade (s) and cause fan failure.

1. An inspection of the cooling fan is required daily.

Check for cracks, loose bolts, bent or loose blades,
Figure 25
and for contact between the blade tips and the fan
shroud. Check the fan to make sure it is securely
mounted. Tighten the bolts if necessary. Replace any
fan that is damaged.

Inspection, Maintenance and Adjustment OP000471

4-17
Check Air Intake System

CAUTION!
Hot engine components can cause burns.
Avoid contact with hot engine components

1. Park the machine on a level surface, lower the

attachment to the ground, set safety lever to "LOCK" HAOA050L
position, and shut down engine. Figure 26

2. Check the engine intake hose, and hose bands for

damage and tightness.
3. 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 FG007670
found on air intake system. Figure 27

Inspect Seat Belt for Proper Operation

Inspect the Structure for Cracks and

Faulty Welds
1. During the daily walk-around inspection and when
greasing the machine, look for any visible damage to
the machine. Repair or replace any damaged parts
before operating the machine.

Check the Operation of All Switches

1. Verify the working condition of all switches before
starting the engine.

Inspection, Maintenance and Adjustment OP000471

4-18
Check the Operation of All Exterior
Lights, Horn and Monitor Lights
1. Turn engine starter switch to the "I" (ON) position and
observe all the indicator lights.
2. Restore operation of any lightbulbs that do not turn
"ON" now.
3. Sound the horn. Repair or replace if required.
4. Turn "ON" and inspect all exterior work lights. Replace
any monitors, burned out bulbs or cracked or broken
housings or lenses.

Start Engine, Check Starting Ability, and

Observe Exhaust Color at Start-up
and at Normal Operating
Temperature. Listen for Any
Abnormal Sounds

Check Operation of All Controls

IMPORTANT
Cold weather operation requires that the operator fully
warm up the hydraulic oil before beginning machine
operation. Follow all warm up instructions listed in the
Operating Instruction section of this manual. Make sure
to cycle oil through all the components, including all
cylinders, both travel motors and the swing motor. Cold
hydraulic oil in the lines and components needs to be
warmed before beginning full operation. If this is not
done, damage to the cylinders or hydraulic motors can
occur.

1. With the engine at rated speed, operate all the

controls.
2. Follow cold weather hydraulic system warm-up
procedures.
3. Note any slow operations or unusual movements.
Determine the cause and repair the fault before
operating.

Inspection, Maintenance and Adjustment OP000471

4-19
50 HOUR / WEEKLY SERVICE

Perform All Daily Service Checks

Grease Front Attachment Pins

Grease every 10 hours for first 100 hours and every 50
hours thereafter.
NOTE: If the unit has been running or working in water the
front attachment should be greased on a 10 hour /
daily basis.
• Position machine as shown below and lower the
front attachment to the ground and shut down
engine
• Press the grease fitting and inject grease with the
grease gun on the marked point
• After injection, clean off the old grease that has
been purged.

A B
D
A

Figure 28 H E G F E FG007675

Reference Reference
Description Description
Number Number
A Boom Cylinder (2 Points) E Bucket Cylinder (2 Points)
B Arm Cylinder (2 Points) F Arm link Joint Pin (1 Point)
C Boom and Boom Swing Joint G Arm and Bucket Joint (1 Point)
(1 Points) H Link Joint (3 Point)
D Boom and Arm Joint (1 Point)

Inspection, Maintenance and Adjustment OP000471

4-20
Grease Dozer Pins and Dozer Cylinder
A. Dozer pins (2 points).
B. Dozer cylinder (2 points).

A
B
B

FG007671
Figure 29

Grease Boom Swing Cylinder and Bracket

There are four grease fittings for the Boom Swing.
A B C
Do not over lubricate, purge oil grease with new. Remove
all purged grease.
A. Boom swing cylinder head (1 points).
B. Swing gear (1 points).
C. Swing bearing (1 points).
D. Boom swing cylinder rod (1 points). FG007678
Figure 30
E. Boom swing bracket (2 points).

Grease Swing Gear Pinion Teeth

1. Inject two or three strokes of grease through the
grease fitting (B, Figure 31).
2. Lift bucket about 20 cm (8 in) from ground. Turn upper E
body 90° at a time for two full turns, greasing the
swing gear pinion teeth at each stop.

D E
FG007673
Figure 31
Grease Swing Bearing
1. Inject grease through the three grease fittings (C,
Figure 31) using a grease gun.
2. Lift bucket about 20 cm (8 in) from ground. Turn upper
body 90° at a time for one full turn, greasing the swing
bearing at each stop.
NOTE: If the unit has been running or working in water
the swing bearing should be greased on a 10
hour / daily basis.

Inspection, Maintenance and Adjustment OP000471

4-21
Drain Water and Sediment from Fuel
Tank
1. Perform this procedure before operating the machine.
2. 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
FG007674
workday to prevent condensation from forming
Figure 32
on the inside walls of the tank.

Check Engine Fan Belt for Cracks, Wear

and Correct Tension (After First 50
Hours)
1. Inspect after first 50 hours of operation and every 250
hours thereafter. For details, See “Check Engine Fan
Belt Tension” on page 4-25.

Change Engine Oil and Filter (After First

50 Hours)
1. Change engine oil and filter after first 50 hours of
operation or rebuild, then every 500 thereafter. For
details, See “Change Engine Oil and Filter” on
page 4-24.

Inspect the Track Assemblies for Proper

Tension and Loose, Worn or
Damaged Parts (Links, Shoes,
Rollers, Idlers)
1. Do a daily walk-around inspection of all components
including the track assemblies. Look for missing,
damaged or excessively worn parts. See “Long Term
Storage” on page 4-55.
2. Jack up each track and perform the two speed travel
motor test.

Inspection, Maintenance and Adjustment OP000471

4-22
250 HOUR / MONTHLY SERVICE

Perform All Daily and 50 Hour Service

Checks

Clean Outer Filter of Air Cleaner

NOTE: Clean outer filter every 500 hours / 3 months of
service.
NOTE: When working in severely dusty conditions, the
service interval should be shortened.

WARNING!
Never clean or attempt to remove the air cleaner filter if
the engine is running.
If using compressed air to clean the filter, make sure
that proper eye protection is worn.

1. Locate the air cleaner assembly.

NOTE: Replace outer filter after cleaning 5 times or
every 2,000 hours / 1 year of service.
2. Remove and clean rubber evacuator valve (1, Figure 2
33) from bottom of air cleaner housing cover (2, Figure
33). Inspect seal lips for wear or damage. Replace
valve if necessary.
NOTE: Install evacuator valve with lips parallel to the
cover. 1
FG007686
Figure 33

3. Remove the access cover (2, Figure 34) by loosening

the latches.
4. Remove the outer filter (3, Figure 34) from the housing.
Do not remove inner filter (4). 2

3 1

FG007683
Figure 34

Inspection, Maintenance and Adjustment OP000471

4-23
5. Clean the outer filter (3, Figure 35) by blowing
compressed air from the inside of the filter towards the
outside. Do not use more than 205 kPa (30 psi) air
pressure.

HAOC570L
Figure 35

6. 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.
7. Clean the inside of the air cleaner body and the inside
of the air cleaner cover. Do not use compressed air.
8. Properly install the air filter and cover.
9. After filter service be sure to install cover with arrows
pointing "UP."

FG000412
Figure 36

Change Engine Oil and Filter

NOTE: Change engine oil and filter after first 50 hours of
operation or rebuild, then every 250 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.

1. Position a larger container under the engine. Remove

cap (1, Figure 37) and install hose to drain the engine
oil. Remove hose and install cap (1).
NOTE: Dispose of drained fluids according to local
regulations. 1

FG007679
Figure 37

Inspection, Maintenance and Adjustment OP000471

4-24
2. Replace engine oil filter by using filter wrench. The
engine oil filter is a spin-on type. See (1, Figure 38).
Remove and discard filter.
3. Install new filter. Apply a small amount of oil around 2
filter gasket. Screw filter on head until gasket contacts
head, turn filter 1/2 turn more.
4. Refill the engine with the correct oil through the oil fill
port (2, Figure 38). Refer to the Lubrication Table of
this manual for the recommended oil for the operating 1
conditions. FG007680

NOTE: See “Fluid Capacities” on page 4-7. for Figure 38

capacity.
5. Start engine. Run engine for five minutes at "LOW
IDLE," and check engine oil pressure light.
6. Shut down engine. Look for signs of leaks at filter.
Recheck oil level after fifteen minutes.

Check Engine Fan Belt Tension 10mm/10kg

FAN ALTERNATOR

IMPORTANT
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.
COMPRESSOR CRANKSHAFT
FG007676
1. Inspect every 250 hours. (Inspect after first 50 hours of Figure 39
operation.)
2. With the engine shut off, check the tension of the fan
belt by pressing downwards on the belt, midway
between the fan pulley and alternator pulley. The belt
should flex approximately 10 mm (0.4 in). See Figure
39. To adjust the belt, loosen the alternator adjustment
plate bolts, adjust the belt tension and retighten the
bolts.

Inspection, Maintenance and Adjustment OP000471

4-25
Check Engine Fan Belt Wear

WARNING!
Keep clear of engine fan and fan drive belts when the
engine is running. Rotating fan and belt contact can
cause injury.

WARNING! Figure 40

When checking, adjusting or replacing drive belts, care

must be taken to prevent accidental cranking of the
engine. Be sure the starter switch is in the "OFF"
position and the controls are tagged.

1. Replace badly worn, greasy or severely cracked belts

immediately. These conditions prevent proper belt
function. Visually inspect the belt. Check the belt for
intersecting cracks. Transverse (across the belt width)
cracks are acceptable. Longitudinal (direction of belt
length) cracks that intersect with transverse cracks are
not acceptable. Replace the belt if it is frayed or has
pieces of material missing.
2. Before installing new belts, make sure all pulley
grooves are clean and not worn. Replace pulley, if
damaged, or if the grooves are worn.
3. All pulley support bearings, shafts, and brackets must
be in working order.
4. 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 naked eye is detrimental to belt performance.
5. Do not force the belts into the pulley grooves by prying
with a screwdriver or pry bar. This will damage the belt
side cords which will cause the belts to turn and result
in complete destruction of the belts in operation.
6. Belts on new machines and replacement belts lose
their tension as they seat into the pulley grooves.
Check the tension of new belts at 50 hour intervals
until tension is stabilized and thereafter, every 250
hours. If the tension falls below the required minimum,
the belt slips damaging the belts and pulley grooves.
NOTE: When operating in abrasive conditions, check
tension every 100 hours.

Inspection, Maintenance and Adjustment OP000471

4-26
Check Oil Level in Travel Reduction
Device (One on Each Side of Unit)
3

WARNING! 1

The gear oil is very hot after the machine has been
operating. Shut all systems down and allow them to 2
cool. Before fully removing any motor case inspection
port plug, etc., loosen the plug slightly to allow FG007685
pressurized air to escape. Figure 41

1. Make sure that the machine is on firm, level ground.

2. Rotate the track until ports (1 thru 3, Figure 41) are in
their proper positions as shown.
3. Loosen fill plug (3, Figure 41) slightly to allow
pressurized air to escape.
4. Remove oil level plug (1, Figure 41).
5. Check oil level. The oil should be near the bottom of
the level plug opening.
6. Add oil through the fill plug (3, Figure 41) opening, if
necessary.
7. Clean and install oil level and fill plugs (1 and 3,
Figure 41).
8. Repeat this procedure on the other travel reduction
device.

Change Oil in Travel Reduction Device

(One on Each Side of Unit) (After
First 250 Hours)
NOTE: Drain and refill oil after first 250 hours of operation or
rebuild, and every 1,000 hours thereafter (See page
4-32).

Replace Hydraulic Oil Return Filter

(After First 250 Hours)
NOTE: Replace hydraulic oil return filter after first 250 hours
of operation or rebuild, then every 1,000 hours
thereafter (See page 4-31).

Inspection, Maintenance and Adjustment OP000471

4-27
Replace Hydraulic Oil Suction Filter
(After First 250 Hours)
NOTE: Replace hydraulic suction filter after first 250 hours of
operation or rebuild, then every 1,000 hours
thereafter (See page 4-31).

Inspect Pins and Bushings of the Front

End Attachments for Signs of Wear

Check Fluid Levels in Batteries and

Battery Charge Levels

Inspect for Any Loose or Missing Nuts

and Bolts

Inspect Fuel System Hose Clamps

Inspection, Maintenance and Adjustment OP000471

4-28
500 HOUR / 3 MONTH SERVICE

Perform All Daily, 50 and 250 Hour

Service Checks

Replace Outer and Inner Air Cleaner

Elements

WARNING!
Never clean or attempt to remove the air cleaner
element if the engine is running.

NOTE: Replace outer element after cleaning 5 times or every

2,000 hours of service.
NOTE: Replace inner element whenever a new outer
element is installed.
If there is clogged filter signal on the gauge panel, use the
following procedure.
2
1. Open the access door at the hood.
2. Remove the evacuator valve (1, Figure 42) and air
cleaner cover (2).
NOTE: Inspect evacuator valve seal lips for wear or
damage. Replace valve if necessary. Install 1
FG007686
evacuator valve with lips parallel to the cover.
Figure 42
3. Remove outer filter (3, Figure 43) from the air cleaner
housing.
4. Clean the air cleaner cover and the inside of the air
cleaner housing.
5. Remove inner filter (4, Figure 43).
6. Clean out inside of air cleaner housing. Do not use
compressed air to blow out housing.
7. Install new inner filter. Do not clean and reuse inner
element.
8. Install new outer filter.
4
9. Install air cleaner cover and evacuator valve.
NOTE: Make sure that all gaskets and cover are 3
properly installed and seated.
FG007687
Figure 43

Inspection, Maintenance and Adjustment OP000471

4-29
Change Fuel Filter

WARNING!
Exchange filter after waiting for engine to cool. Be
careful of fire hazards. Do not smoke.

1. Locate fuel filter inside engine compartment.

2. Position a small container under fuel filter (1, Figure
44).
3. Unscrew fuel filter from head assembly. Discard fuel
filter.
NOTE: Dispose of drained fluids according to local
regulations.
4. After cleaning filter head, install new fuel filter. Screw
filter on head until gasket contacts head, and turn filter
1/2 turn more with a filter wrench.
NOTE: Coat fuel filter gasket with fuel.
NOTE: Fill fuel filter with clean fuel. This will help
reduce fuel system priming.

Fuel System Priming

If air remains in the fuel inlet line to the engine, it may
cause the engine to run in an abnormal condition. Air may
impact the starting capability of the engine, and may also
result in surging engine speeds.
If the machine happens to have run out of fuel, or if the 2
fuel filter has been replaced, air may need to be bleed 1
using the following procedure:
1. Shut down engine.
FG007684
2. Fill fuel tank.
Figure 44
3. Loosen plug (2, Figure 44).
4. Turn starter switch to the "I" (ON) position to activate
electric fuel pump which sends fuel under pressure to
each injection nozzle and to bleed off pipes of each
nozzle holder, and then returns air the fuel tank
5. After air has been bleed, tighten plug (2, Figure 44) in
fuel prefilter head.
6. Start engine and check fuel system for leaks.

Inspection, Maintenance and Adjustment OP000471

4-30
1,000 HOUR / 6 MONTH SERVICE

Perform All Daily, 50, 250 and 500 Hour

Service Checks

Replace Hydraulic Oil Return Filter

NOTE: Change hydraulic oil return filter after first 250 hours
of operation or rebuild, and every 1,000 hours
thereafter.

1
WARNING!
3 2
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. Loosen the hydraulic
breather cap slightly to allow the pressurized air to vent.
After the pressure has been released, it is safe to
4 FG008080
remove either the fill cap or service covers or drain
water from the tank. Figure 45

IMPORTANT
Make sure to clean any dirt or water from the top of the
hydraulic tank, especially around the fill port and filter
ports.

1. Park machine on firm, level ground. Lower the front

attachment to the ground and shut down engine.
2. Loosen the breather cap (1, Figure 45) slightly to
release the internal pressure.
7
3. Remove bolts (2, Figure 45) and oil filter set (3).
4. Remove bolts (5) and filter locker.
5. Discard the filter (7). Install new filter.
5 6
6. Clean the oil filter set (3) and O-ring (4, Figure 45).
7. Install all parts in reverse order. FG008081
8. Run engine for ten minutes at low idle to purge air Figure 46
from circuit.
9. Check level in hydraulic oil tank (See page 4-13). Add
oil if necessary.

Inspection, Maintenance and Adjustment OP000471

4-31
Change Oil in Travel Reduction Device
(One on Each Side of Unit)
3

WARNING! 1

The gear oil is very hot after the machine has been
operating. Shut all systems down and allow them to 2
cool. Before fully removing any motor case, inspection
port plug, etc., loosen the plug slightly to allow FG007685
pressurized air to escape. Figure 47

NOTE: Drain oil after first 250 hours of operation or rebuild,

and every 1,000 hours thereafter.
1. Make sure that the machine is on firm, level ground.
2. Rotate the track until ports (1 thru 3, Figure 47) are in
their proper positions as shown.
3. Place a container under drain plug (2, Figure 47) and
remove plugs (1 thru 3) to drain the travel reduction
gear oil.
NOTE: Dispose of drained fluids according to local
regulations.
4. Install drain plug (2, Figure 47). Refill the travel
reduction gear case with fluid through fill port (3) until
the fluid level is at port (1). Install level plug (1) and fill
plug (3).
NOTE: See “Fluid Capacities” on page 4-7. for
capacity.
5. Repeat this procedure on the other travel reduction
device.

Replace Hydraulic Oil Suction Filter

NOTE: Replace hydraulic suction filter after first 250 hours of
operation or rebuild, then every 1,000 hours
thereafter (See page 4-34).

Inspection, Maintenance and Adjustment OP000471

4-32
2,000 HOUR / YEARLY SERVICE

Perform All Daily, 50, 250, 500 and 1,000

Hour Service Checks

Change Radiator Coolant

WARNING!
Allow the engine to cool before releasing the radiator
cap. Make sure to loosen the cap slowly to release any
remaining pressure.
Radiator cleaning is performed while the engine is
running. Take extreme caution when working on or near ARO1760L
a running engine. Make sure to lock out and tag the Figure 48
controls notifying personnel that service work is being
performed.
Do not remove the radiator cap unless it is required.
Observe the coolant level in the coolant recovery tank.

1. Slowly open the radiator cap to allow any pressure to

escape.
2. Place a container under the radiator and open the
drain valve (2, Figure 49).
NOTE: Dispose of drained fluids according to local
regulations.
3. Install drain plug, and close drain valve after coolant
1
has completely drained from system.
4. Fill cooling system with a flushing solution. FG007688
5. Run engine at low idle until the coolant temperature Figure 49
gauge reaches the "BLUE ZONE." Run engine for
another ten minutes.
6. Allow engine to cool.
7. Drain flushing fluid and fill system with water.
8. Run engine again to allow water to completely
circulate.
9. After allowing engine to cool, drain water and fill
system with proper antifreeze mixture for ambient
temperature. Refer to coolant concentration table. See
“Antifreeze Concentration Tables” on page 4-53.
10. Run engine without radiator cap installed, so all air will
be purged from system. Fill radiator to fill neck.
11. Drain and fill radiator coolant recovery tank.

Inspection, Maintenance and Adjustment OP000471

4-33
Hydraulic Oil Exchange and Suction
Filter Replacing

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.
ARO1760L
The hydraulic tank is pressurized. Loosen the breather
cap to allow the pressurized air to vent. After the Figure 50
pressure has been released, it is safe to remove either
the fill cap or service covers.

IMPORTANT
Make sure to clean any dirt or water from the top of the
hydraulic tank, especially around the fill port and filter
ports.
Hydraulic oil change interval is 2,000 hours, only when
DOOSAN Genuine Oil is used. If another brand of oil is
used, guaranteed change interval is 1,000 hours.

NOTE: Based on the type of excavating being completed,

the working conditions (extremely hot or dusty) and
the extra front end attachments being used (hydraulic
breaker, etc.), the hydraulic fluid will need to be
changed more frequently.
1. Park machine on firm, level ground. Swing upper
structure perpendicular (90°) to tracks. Lower boom and
position bucket on ground as shown in Figure 51.
2. Set safety lever on "LOCK" position.
3. Shut down engine.
4. Release pressurized air from hydraulic tank by rotating
breather cap (1, Figure 51).

FG007689
Figure 51

Inspection, Maintenance and Adjustment OP000471

4-34
5. Drain hydraulic oil from tank into a container capable of
holding 40 liters (11 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 FG000129

FG007690
disposed of according to local regulations. Figure 52

6. Carefully remove bolts and cover (2, Figure 53) from

top of hydraulic oil tank.
7. Remove the suction filter (3).
1
8. Install new suction filter. Fill the hydraulic oil tank.
Check level using sight gauge on side of tank. 2
9. Install all parts in reverse order.

FG008082
Figure 53

Check Alternator and Starter**

**These checks need to be completed by an authorized
DOOSAN dealer.

Check All Rubber Antivibration Shock

Mounts

Inspection, Maintenance and Adjustment OP000471

4-35
Perform and Record the Results of the
Cycle Time Tests

Inspect Machine to Check for Cracked

or Broken Welds or other Structural
Damage

Check, Adjust Valve Clearance **

Check Head Bolt Torques

Inspection, Maintenance and Adjustment OP000471

4-36
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.
Always replace all related parts such as gaskets and
O-rings. Use only original equipment manufacturers parts.

Major Component Parts Name to be Exchanged Periodically Time to Exchange

Fuel hose (Tank to filter).
Engine Fuel hose (Tank to fuel injection pump).
Heater hose (Heater to engine).
Pump suction hose.
Body Pump discharge hose.
2 years or 4,000
Swing hose.
hours
Hydraulic Boom cylinder line hose.
System Arm cylinder line hose.
Work
Bucket cylinder line hose.
Device
Pilot hose.
Boom swing cylinder line hose.

Inspection, Maintenance and Adjustment OP000471

4-37
12,000 HOUR / SIX YEAR
SERVICE

Hose In-service Lifetime Limit (European

Standard ISO 8331 and EN982 CEN)
European regulations state that the in-service life of any
hydraulic hose may not exceed six 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.
• In-service lifetime of hoses fitted on a machine
can never exceed 6 years, but replace hoses
described in “Major Parts - Periodic Replacement”
on page 4-37, every 2 years. Always replace
hoses having exceeded the allowed in-service
lifetime irrespective of the external appearance/
wear.
• Always store hoses in a dark place at a maximum
of 65% relative humidity, between 0°C (32°F) and
35°C (95°F) but as close as possible to 15°C
(59°F) and away from copper, manganese or tube
generating Ozone.

Inspection, Maintenance and Adjustment OP000471

4-38
AIR-CONDITIONING SYSTEM

Check Air Conditioner Hoses

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.

Check Magnetic Clutch

Check the magnetic clutch for dirt and interference.
Push the "A/C" switch to energize magnetic clutch and
check the magnetic clutch.

Check Belt Tension

NOTE: See “Check Engine Fan Belt Tension” on page 4-25.

Inspection, Maintenance and Adjustment OP000471

4-39
BOLT AND NUT INSPECTION
Inspect ALL fasteners after the first 50 hours of operation
and every 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
No. Point to be Inspected Dia. Qty. Head
Mm Size Nm kg•m ft lb
1 Engine vibration dampening bolts 12 4 19 73.5 7.5 54
Bolt 10 4 17
2 Engine bracket 63.7 6.5 47
Nut 10 (2) 4 17
3 Hydraulic and fuel tank mounting bolts 10 8 17 42.2 4.3 31
PF1/4 26.5-29.4 2.7-3.0 20-22
4 Hydraulic hose and pipe joint PF3/8 46-51 4.7-5.2 34-38
PF1/2 56-62 5.7-6.3 41-46
5 Pump mounting bolt 12 2 19 112.8 11.5 83
6 Control valve mounting bolt 8 4 13 21.6 2.2 16
7 Control valve base mounting bolt 10 4 17 42.2 4.3 31
8 Swivel mounting bolt 14 4 22 176.5 18 130
9 Canopy mounting bolt 12 5 19 112.8 11.5 83
10 Cabin mounting bolt 12 5 19 112.8 11.5 83
11 Cabin stopper bolt 16 4 24 269.7 27.5 199
Swivel bearing mount- swiveling body 12 16 19 112.8 11.5 83
12
ing bolt track 12 16 19 112.8 11.5 83
13 Traveling body mounting bolt 12 18 19 112.8 11.5 83
14 Sprocket mounting bolt 12 18 19 112.8 11.5 83
15 Lower roller mounting bolt 20 12 30 338 34.5 249
16 Cover mounting bolt 8 28 13 21.6 2.2 16
17 Counterweight mounting bolt 20 3 30 539 55 397

NOTE: At installation, remove rust, sand, dirt and dust.

At installation, lubricate to reduce abrasion.
Apply Loctite to lower roller mounting bolts.
The top 2 notes above are not keyed to anything

Inspection, Maintenance and Adjustment OP000471

4-40
BUCKET

Bucket Tooth Replacement

WARNING!
Due to the possibility of flying metal objects, always
wear safety helmet, protective gloves and eye protection
when changing bucket teeth.
Curl the bucket upwards and place the round rear
surface of the bucket firmly on the ground. 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.

Figure 54

1. On a routine basis, inspect the bucket teeth to make

sure that tooth wear or breakage has not developed.
Do not allow the replaceable bucket teeth to wear
down to the point that the bucket is exposed. See
Figure 54.

Inspection, Maintenance and Adjustment OP000471

4-41
2. Place bucket, with wooden blocks under it, as shown in
illustration.
Move front edge of bucket up slightly to make work
easier, if desired. Do not raise it too far or the teeth
may cause injury if fallen on.
3. Check tooth point and side cutter for wear or
looseness.
4. Tighten tooth points and side cutters or replace if
damaged:
A. Remove nuts (1), washers (2) and bolts (3).
Remove side cutters (4). (Each side cutter has
three sets of bolts and nuts.)
B. Remove nuts (5) and bolts (6). Remove tooth
point. (A tooth point has two sets of bolts and
nuts)
Figure 55
C. Reinstall parts in reverse order of disassembly.
D. After the first operation following point
replacement, retighten nuts.

Inspection, Maintenance and Adjustment OP000471

4-42
Bucket O-ring Replacement

WARNING!
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.

1. Inspect the bucket O-rings on a routine basis. If worn

or damaged, replacement is necessary.

Figure 56

2. Roll the old O-ring (1) onto the bushing (2) around the
1 2 4
bucket pin (3).
3. Remove the bucket pin and move the arm or bucket
link (4) out of the way.

FG007695
Figure 57

4. Remove the old O-ring and temporarily install the new

1 2 3
O-ring (1) onto the bucket bushing (2). Make sure that
the O-ring groove on both the bucket link (3) and
bushing have been cleaned.
5. Realign the arm or link with the bucket pin hole and
insert the bucket pin (3).

FG007696
Figure 58

Inspection, Maintenance and Adjustment OP000471

4-43
6. Roll the new O-ring (1) into the O-ring groove.
1

FG007697
Figure 59

Inspection, Maintenance and Adjustment OP000471

4-44
Bucket Shimming Procedures

New Bucket Installation

1. If a new bucket is being installed on excavator,
measure inside dimension between bucket ears and
outside dimension across arm mounting boss.
2. Subtract clearance on both sides from difference of two
and shim accordingly, before assembly.

WARNING!
To check end play (side to side) clearance at
bucket attachment point, the bucket must be free to
move but at all other times lower it to the ground
or use support blocks to immobilize this assembly.
Shut off engine and tag and lock out controls to
prevent movement during this procedure.

Shimming Procedures for Installed Bucket

1. With bucket attached, curl bucket and arm outward and
lower boom so bucket teeth are pointing away from
excavator, just a few inches off ground. This position
provides easy accessibility for dimensional
measurements.
2. Force bucket to one side and check for end play (side
to side) clearance under O-rings at attachment point.
Clearance should be between 0.2 - 0.7 mm (0.008 -
0.027 in) on each end of arm boss, between side face
of boss and inside edge of ear busing. Too tight a fit
can cause excessive wear while too much clearance
may produce excessive noise and potentially hazardous
slack control.
3. Recheck end play by forcing bucket towards opposite
side and repeating clearance measurements.
4. If an adjustment is required, remove bolt and pin. Add
or remove shims as required. Install pin and bolt. Figure 60
Torque blots to 42 Nm / 4.3 kg•m (31 ft lb).

Inspection, Maintenance and Adjustment OP000471

4-45
Replace Bucket

WARNING!
When removing pin, metal pieces can fly out and cause
injury. Be sure to wear safety glasses or goggles, safety
hat and safety gloves to prevent injuries.

Bucket Disassembly
1. Place bucket as shown in illustration.

IMPORTANT B

In next step, O-rings are removed with pins. Be A

careful not to damage them.

2. Remove bolts holding pins A and B, remove pins, and FG007692

remove bucket.
Figure 61
NOTE: If pins do not come out easily, the bucket may
be resting on the ground too "heavily."

Bucket Installation
1. Clean and grease pins and pin holes.
2. Install new bucket as shown in illustration.
3. Install pins, aligning arm hole A with dump link hole B. B
Install O-rings. Dump
A link
4. Apply grease to pins.
5. Run engine at low idle and move bucket slowly through
one stroke to make sure parts are installed correctly.
FG007693
Figure 62

Inspection, Maintenance and Adjustment OP000471

4-46
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.
Battery acid could cause blindness if splashed into the
eyes. If acid gets into the eyes, flush them immediately
with large quantities of water and see a doctor at once.
If you accidentally drink acid, drink a large quantity of
water or milk, beaten egg or vegetable oil. Call a doctor
or poison prevention center immediately.
When working with batteries, always wear safety glasses
or goggles.
Battery generates hydrogen gas, so there is danger of
an explosion. Do not bring lighted cigarettes near the
battery, or do anything that will cause sparks.
Before working with batteries, shut down engine and
turn the starter switch to the "O" (OFF) position.
Avoid short-circuiting the battery terminals through
accidental contact with metallic objects, such as tool.
When removing or installing, check which is the positive
(+) terminal and negative (-) terminal.
When removing the battery, first disconnect the negative
(-) terminal. When installing the battery, first connect the
positive (+) terminal.
If the terminals are loose, there is danger that the
defective contact may generate sparks that will cause an
explosion. When installing the terminals, install them
tightly.

Batteries in Cold Weather

In colder weather a greater drain is placed on the batteries
when they are used for the preheat cycle and when starting
a cold engine. Battery performance decreases as the
temperature gets lower.
In extremely cold weather, remove the batteries at night and
move them to a warm location. This will help to keep them
at a higher power level.

Inspection, Maintenance and Adjustment OP000471

4-47
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.

Check Charging State

FG007701
Check charging state through the charging indicator.
Figure 63
• GREEN: Sufficiently charged.
• BLACK: Insufficient charged.
• TRANSPARENT: Replace battery.

Check the Battery Terminals

Be certain that the battery is held securely in its
compartment. Clean the battery terminals and the battery
cable connectors. A solution of baking soda and water will
neutralize acid on the battery surface, terminals, and cable
connectors. Petroleum jelly or grease can be applied to the
connectors to help prevent corrosion.

Battery Replacement
When the charging indicator indicates transparency state, FG007702
replace the battery. The batteries should always be replaced Figure 64
in pairs.
Using an old battery with a new one will shorten the life
span of the new battery.

Fuses
1. The fuses in the fuse box are used to protect the
various electrical circuits and their components from
O X
being damaged. See Figure 65. The fuses used are
standard automotive type fuses.
2. The section on “Fuse Identification” on page 4-49, lists
the circuits and the fuse amperage required for each
circuit. If a fuse blows, determine the cause and repair
any faults or failures.
HAOC670L
3. Do not insert a higher amperage fuse into a lower
Figure 65
amperage slot. Serious damage to the electrical
components or fire can result.

Inspection, Maintenance and Adjustment OP000471

4-48
 CAUTION!
Before replacing a fuse, be sure to turn starter switch to
"O" (OFF) position.

Fuse Box
There is a fuse box (Figure 66) in the electric box which is
under the seat. The fuses prevent electrical devices from
overloading or shorting.
A decal attached to the fuse box's cover indicates the
function and amperage of each fuse.
Spare fuses are mounted on the inside of fuse box's cover.
(One each of a 10A, 15A, 20A and 30A.)
Change a fuse if the element separates. If the element of a
FG007500
new fuse separates, check the circuit and repair the circuit.
Figure 66

CAUTION!
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.

Fuse Identification

Fuse Box
No.
Name Capacity
1 Rotating Beacon 10A
2 Spare 10A
3 Horn, Travel Alarm, Fuel Pump 10A
4 Quick Clamp, High-speed 10A
5 Cigar Lighter 15A
6 Wiper, Washer, Stereo 15A
7 Pilot Cut Off 15A
8 Spare 30A
FG007491
9 Air Conditioner, Compressor 20A
Figure 67
10 Heater 15A
11 Condenser 15A
12 Working Light, Head Light 30A
13 Gauge Panel 10A
14 Cabin Light, Hour Meter 10A

Inspection, Maintenance and Adjustment OP000471

4-49
ENGINE COOLING SYSTEM

General
Keeping an engine's cooling system in peak operating
condition can have many benefits in keeping a machine in
good operating condition. A properly functioning cooling
system will; improve fuel efficiency, reduce engine wear, and
extend component life.
Always use distilled water in the radiator. Contaminants in
tap water neutralize the corrosion inhibitor components. If
tap water must be used, it should not exceed 300 ppm
hardness, or contain more than 100 ppm of either chloride
or sulfate. Water that has been treated with a water softener
also contains salt that will cause corrosion of components.
Water from creeks and stagnant pools usually contains dirt,
minerals and/or organic material that are deposited in the
cooling system and impair cooling efficiency. Distilled water
is the best.
Make at least a minimum mixture of 40% antifreeze with
60% distilled water for adding additional fluid to the system
during normal maintenance. This level will help maintain the
additive concentration of the system. Check the coolant
every 500 hours.
Engine overheating is often caused by bent or clogged
radiator fins. The spaces between the fins can be cleaned
by use of air or water under pressure. When straightening
bent fins, use care not to damage the tubes or break the
bond between the fins and the tubes.

CAUTION!
Maintaining the proper anticorrosive additive levels in
antifreeze will help protect the engine and other
components from becoming corroded.
If anticorrosive additive levels are not properly
maintained and monitored, server damage to the cooling
pump and cylinder liners may result. This corrosion can
also result in the radiator tubes becoming clogged and
loosing their heat transfer efficiency. The engine (Model:
DV11) uses a wet-type cylinder liner design, which
requires, a high efficiency cooling system flow, to
maintain proper engine temperatures.
The coolant and its additives can be checked by using
coolant test paper (No: 60.99901-0038).

Inspection, Maintenance and Adjustment OP000471

4-50
 WARNING!
Pressure at air nozzle must not exceed 2.1 kg/cm2 (30
psi). Always wear goggles when using compressed
air.
Do not pour cold water into radiator when engine is
very hot and water level is below the top of the
tubes. Such action could result in damage to engine
cylinder heads.

Heavy duty diesel engines require a balanced mixture of

water and antifreeze. Drain and replace the mixture every
year or 2,000 hours of operation, whichever comes first.
This will eliminate buildup of harmful chemicals.
Antifreeze is essential in any climate. It broadens the
operating temperature range by lowering the coolant's
freezing point and by raising its boiling point. Do not use
more than 50% antifreeze in the mixture unless additional
freeze protection is required. Never use more than 68%
antifreeze under any condition.

Measuring the Concentration of Coolant

The coolant and its additives can be checked by using
coolant test strips (No: 60.99901-0038). Use the following
procedure to conduct the test:
1. With a coolant temperature of 10° - 55°C (50° -
131°F), drain 1 liter (1 U.S. quart) it from the radiator
into a clean plastic container.
NOTE: Do not take the sample from the coolant
recovery tank. Recovery tank coolant
concentration can differ from the concentration
level of coolant in the radiator.
2. Dip test strip, into coolant sample for 3 - 5 seconds.
Remove strip and excessive coolant by giving the strip
one shack.
3. Wait for 45 seconds, for the test strip to change color.
NOTE: Measuring time should not be more than 75
seconds. If it is over this time limit, the color will
be changed and an inaccurate reading will
result.
4. Compare the color of the test strip with the color table
on the outside of test strip container bottle, and
determine what numeric value corresponds to the color
in the table.

Inspection, Maintenance and Adjustment OP000471

4-51
 A. Check antifreeze concentration levels by
comparing the color change at the end of test
paper, with the green spectrum range, with the
green symbol on the upper portion of the
container bottle.
NOTE: A suitable concentration indicator should
be between 33% and 50%).
B. Check the anticorrosive additives, by comparing
brown color in the middle range of the test strip
and pink color on the lower part of the test strip,
with the brown and pink spectrum range. Where
the brown (vertical) color and pink (horizontal)
color intersects represents the anticorrosive
additive level.
NOTE: A reading between 0.3 and 0.8, represents
an adequate additive level.
5. Correct the antifreeze concentration and additive levels.
A. If anticorrosive additive level is below 0.3, add
100% pure antifreeze to the radiator.
B. If anticorrosive additive level is greater 0.8, add a
50% distilled water and antifreeze mixture to lower
the additive reading.
NOTE: In either case keep the antifreeze concentration
level between 33% and 50%.
6. Run the engine to recirculate the coolant mixture. Be
sure that engine reaches operating temperature to
ensure a thorough mix. Shut down engine and retest
antifreeze.
NOTE: When making adjustment, drain 1 liter (1 U.S.
quart) of coolant from the radiator. Add 30 cc (1
fl oz) at a time to the drained fluid. Keep track of
how many cc's (fl oz's) were added to the 1 liter
(1 U.S. quart) to obtain a proper reading. Then
multiply that number times the total system
capacity of liters (U.S. quarts). Add that amount
to the radiator.
Example: If 1 liter needs 90 cc to obtain proper
reading. Then system capacity of 40
liters x 90 cc = 3,600 cc (3.6 liters) of
correction fluid.

Inspection, Maintenance and Adjustment OP000471

4-52
Types of Antifreeze
There are two main classifications of antifreeze available on
the market today.
1. Ethylene Glycol - Standard Life Antifreeze
2. Propylene Glycol - Extended Life Antifreeze
Ethylene glycol (standard life antifreeze) has been on the
market for many years. Its chemical properties do not
provide the improved corrosion resistance that propylene
glycol (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. Some of the colors are pink, red, orange
and yellow. There are even some that come in a blue-green
color. The blue-green color makes it very difficult to tell the
difference of what type of antifreeze is in a cooling system.
The colors are only a dye added to the clear antifreeze. Do
not rely on color. Keep careful machine records of what
brand and type of antifreeze is used in the unit. If you are
unsure of what type of antifreeze is in the system, drain and
flush the system.
NOTE: Do not mix ethylene glycol and propylene glycol
antifreeze together. If the two are mixed, the
protection level will be reduced to the level of the
ethylene glycol.

Antifreeze Concentration Tables

Ethylene Glycol - Standard Life Antifreeze
(1,000 Hour / 6 Months)
Ambient Temperature Cooling Water Antifreeze
-10°C (14°F) 80% 20%
-15°C (5°F) 73% 27%
-20°C (-4°F) 67% 33%
-25°C (-13°F) 60% 40%
-30°C (-22°F) 56% 44%
-40°C (-40°F) 50% 50%

Propylene Glycol - Extended Life Antifreeze

(2,000 Hour / Yearly)
Ambient Temperature Cooling Water Antifreeze
-10°C (14°F) 78% 22%
-15°C (5°F) 71% 29%
-20°C (-4°F) 65% 35%
-25°C (-13°F) 59% 41%
-30°C (-22°F) 55% 45%
-40°C (-40°F) 48% 52%

Inspection, Maintenance and Adjustment OP000471

4-53
HANDLING OF ACCUMULATOR

WARNING!
Even though the engine is stopped, the hydraulic
accumulators for the pilot system are still charged. Do
not disconnect any pilot system hoses until accumulator
pressure has been released from the circuit. To release
pressure, turn the starter switch to the "I" (ON) position
and operate all hydraulic control levers and forward/
reverse travel levers. Even though the engine is
shutdown hydraulic actuated components may move
while releasing pilot pressure. Keep all personnel away
from excavator while performing this operation.
• Set safety lever on "LOCK" position after
stopping engine.
• DO NOT mishandle accumulator (s). They are
very dangerous because they contain
high-pressure nitrogen gas.
• DO NOT punch a hole or apply heat or fire to
an 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.

Release pilot accumulator pressure using the following

procedure:
1. Park machine on firm, level ground. Lower the front
attachment to the ground and shut down engine.
2. Set safety lever on "RELEASED" position.
3. Turn starter switch to the "I" (ON) position.
4. Fully stroke work and travel levers in all directions.
5. Set safety lever on "LOCK" position.
FG007703
6. Turn key to "O" (OFF) position and remove from starter
switch. Figure 68

7. Remove accumulator by unscrewing it slowly.

Inspection, Maintenance and Adjustment OP000471

4-54
LONG TERM STORAGE

IMPORTANT
When storing machine, position as shown in illustration
to protect the cylinder rod. Protect the cylinder against
rust.

Perform the following if storing the excavator for more than

one month.
FG007662
Figure 69

Conditions Maintenance Required

Cleaning 1. Pressure wash the undercarriage and wheel drive assemblies.
Inspect for damage or loose or missing parts.
Lubrication 1. Perform all daily lubrication procedures.
2. Apply a coating of light oil to the exposed plated metal
surfaces, such as hydraulic cylinder rods, etc.
3. Apply a coating of light oil to all the control linkages and
control cylinders (control valve spools, etc.).
Battery 1. Remove the battery from the excavator and store in a warm
place. Fully charge battery before storing.
Cooling System 1. Inspect the coolant reserve tank to make sure that the
antifreeze level in the system is at the correct level.
2. Every 90 days or 750 hours on the hour meter, use a
hydrometer to measure the protection level of the coolant.
Refer to the antifreeze/coolant protection chart to determine the
amount of protection the cooling system requires. Add coolant
as required.
Hydraulic System 1. Once a month, start the engine and follow the "Hydraulic Oil
Warm-up" procedures listed in this manual.

After Storage
1. Check fluid levels and check for missing parts, then
start engine.

IMPORTANT
Sudden operation may damage seals and gaskets.

2. When operating cylinders, run engine at idle and

operate each control 3 or 4 times to lubricate hydraulic
components.

Inspection, Maintenance and Adjustment OP000471

4-55
MAINTENANCE IN SPECIAL
CONDITIONS
NOTE: See “Operation Under Unusual Conditions” on
page 3-38 for other recommendations.

Conditions Maintenance Required

Operating in mud, water or rain. 1. Perform a walk around inspection to check for
any loose fittings, obvious damage to the
machine or any fluid leakage.
2. After completing operations, clean mud, rocks
or debris from the machine. Inspect for
damage, cracked welds or loosened parts.
3. Perform all daily lubrication and service.
4. If the operations were in salt water or other
corrosive materials, make sure to flush the
affected equipment with fresh water.
Operating in an extremely dusty or hot 1. Clean the air intake filters on a more frequent
environment. basis.
2. Clean the radiator and oil cooler fins to
remove embedded dirt and dust.
3. Clean the fuel system intake strainer and fuel
filter more frequently.
4. Inspect and clean the starter and alternator as
required.
Operating in rocky terrain. 1. Check the undercarriage and wheel drive
assemblies for damage or excessive wear.
2. Inspect for loose or damaged fittings or bolts.
3. Inspect wheels and tires for damage.
4. On a more frequent basis, inspect the front
end attachments for damage or excessive
wear.
5. Install a top guard and front guard as required
for protection against falling rock.
Operating in extreme cold. 1. Use the proper fuel for the temperature
conditions.
2. Using a hydrometer, check the antifreeze to
make sure that it is providing the proper cold
weather freeze protection.
3. Verify the condition of the batteries. In
extremely cold weather remove the batteries at
night and store them in a warmer area.
4. Remove mud build up as soon as possible to
prevent it from freezing to the undercarriage
and causing damage.
Falling objects/stones 1. Install overhead guard on cabin. Contact your
Daewoo dealer.
Salt water or air 1. Wash the machine thoroughly to remove salt.

Inspection, Maintenance and Adjustment OP000471

4-56
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. Warm up the
engine to prevent stalls, travel the excavator to an area
that provides level, uniform ground support and/or use
support blocks when necessary.
The track adjusting mechanism is 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 tightened down
position. Bleed off pressure slowly and keep your body
away from the valve at all times. If there is problem in
the fitting thread, the valve or fitting might be ejected at
high-speed, causing a fatal injury.

Track shoe link pins and bushings wear with normal usage,
reducing track tension. Periodic adjustment is necessary to
compensate for wear and it may also be required by
working conditions.

Inspection
1. Turn upper body so it is at a 90° angle to the tracks.
NOTE: On rubber crawlers, move machine body so
seam of crawler pad is on the axle center line,
then turn body. FG007704
Figure 70
2. Track tension is checked by jacking up one side of the
excavator. See Figure 70. Place blocking under frame
while taking measurement.
3. Measure clearance between track roller and track
contact surfaces. Clearance should be approximately 10
- 15 mm (0.39 - 0.59 in)
NOTE: This measurement can be thrown off if there is
too much mud or dirt or other material in the
track assembly. Clean off the tracks before
checking clearance.
10~15mm

FG007705
Figure 71

Inspection, Maintenance and Adjustment OP000471

4-57
 NOTE: For machines with steel crawlers (optional),
checking and adjustment steps and the
clearance are the same.

Figure 72

WARNING!
The track adjusting mechanism is 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 tightened down position. Bleed off pressure
slowly and keep your body away from the valve at
all times. If there is problem in the fitting thread,
the valve or fitting might be ejected at high-speed,
Figure 73
causing a fatal injury.

How to Adjust Tension

1. Apply grease through grease fitting.
2. Move track forward and backward to distribute grease
and readjust tension if necessary.
3. If tension cannot be increased, replace pin and
bushing, or, on rubber crawlers, replace cylinder seal
or crawler.

Figure 74

To Reduce Tension
1. Loosening the cartridge valve causes grease to drain
out and track tension to decrease. Loosen valve slowly
a maximum of 1 to turns.
2. When crawler tension is correct, tighten cartridge valve
to 59 - 88 Nm / 6-9 kg•m (43 - 65 ft lb)
3. Recheck tension by moving track forward and
backward.
4. Recheck tension and adjust as necessary.
Figure 75

Inspection, Maintenance and Adjustment OP000471

4-58
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.
1. With the engine stopped, remove vent plug (Figure 76)
to see if any oil is present.
2. If oil is not present, fill pump with oil through port
(Figure 76).
3. Install vent plug (Figure 76) first. FG007711
Figure 76
4. Start engine and run it for several minutes at low idle
engine speed. This will pressurize the hydraulic oil tank
and system.
5. Slowly loosen vent plug (Figure 76) several turns, until
hydraulic oil flows out of plug. This shows that air has
been released.
6. Tighten the plug (Figure 76).

Hydraulic Cylinders

IMPORTANT
If cylinders are operated in high idle after the hydraulic
system has been drained or the cylinder has been
rebuilt, damage to piston packing and seals may occur.
Always vent air from cylinders at low idle and at a slow
speed.

1. Run engine at low idle. Extend and retract each

cylinder to within 100 mm (4 in) of fully stroking it 4 -
5 times.
2. Operate fully extend and retract each cylinder 3- 4
times.
3. Repeat procedure until cylinders extend and retract
smoothly.

Inspection, Maintenance and Adjustment OP000471

4-59
Travel Motor
NOTE: Perform this only when oil is drained from travel
motor
1. Shut down engine
2. Disconnect drain hose (Figure 77) and fill motor case
with hydraulic oil.
3. Connect drain hose.
4. Start engine and set engine speed control dial to "LOW
FG007712
IDLE." Run the engine for one minute and slowly drive
Figure 77
excavator forwards and backwards.

General Venting
1. After venting air from all components, shut the engine
down and check the hydraulic oil level. Fill hydraulic oil
tank to "H" mark on sight gauge.
2. Start engine and operate all controls again, run engine
for five minutes to ensure all systems have been vent
and purged of air. Set engine speed to "LOW IDLE,"
and check hydraulic oil level again. Add oil as
necessary.
3. Check for oil leaks and clean all fill and venting
locations.

Inspection, Maintenance and Adjustment OP000471

4-60
 OP000472

5Transportation
Obey all local, state or federal regulations for the
transportation of the excavator. If unsure of regulations
check with local authorities.
Check the intended route for road width, overhead
clearances, weight restrictions, and traffic control regulations.
Special approval or permits may be required.

LOADING AND UNLOADING

WARNING!
When transporting the machine, know the width, height,
length and weight.
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 the ramp being used can handle the
weight of the machine. If required, add blocking under
the ramp for additional support.
Make sure that the ramp surface is free of grease or
mud that could cause the machine to slip or slide.
Make sure that the trailer is parked on firm, level
ground before attempting to load/unload the excavator.
If it is required to turn the machine while it is on the
trailer, make sure to do this at the slowest engine and
travel speeds possible.
Make sure to secure the excavator onto the trailer as
required by local transportation laws.

Total Height Total Width Total Length Weight Remarks

2.5 m Boom
2,515 mm 1,700 mm 4,650 mm 3.65 metric tons
1.25 m Arm
(8' 3") (5' 7") (15.3 in)
300 G Shoe

Transportation OP000472
5-1
1. Make sure that the trailer is parked on firm, level
ground. See Figure 1.
2. Make sure that the ramps that are being used are
designed to handle the weight of the excavator. If 90 ~ 110
required, add blocking under the ramp to provide
additional support.
3. The ramp angle should be less than or not exceeding
a 15° angle. Ramps steeper than this may cause a
problem when loading or unloading.
15 FG007587
Figure 1

4. Set the travel speed selector switch to "O" (OFF)

position. See Figure 2.
5. Set engine speed to "LOW IDLE."

I
FG008127
Figure 2

6. If the machine is equipped with work equipment, set

the work equipment at the front, and travel forward to
load it.
90 ~ 110

15 FG007587
Figure 3

7. Extend bucket and arm cylinders to maximum length

and then lower the boom slowly.

FG007665
Figure 4

Transportation OP000472
5-2
8. Set safety lever on "LOCK" position.
Lock

Unlock

FG007566
Figure 5

9. Shut down engine by turning key to "O" (OFF) position

(Figure 6). O I
10. Remove key from starter switch.

FG001364
Figure 6

11. Make sure to secure the excavator onto the trailer

before transporting. Place blocking (1, Figure 7) in front
of and behind each track. Use chains or cable
tie-downs (2) as required by local transportation laws.
12. Refer to the Dimensions for Transportation table and
drawing for overall machine height and width
measurements. Make sure to position the excavator as
1
shown. If not transported in this position, the height
measurements may be different.
1
2
FG007682
Figure 7

Transportation OP000472
5-3
LIFTING WITH SLING

WARNING!
Improper lifting can allow load to shift and cause injury
or damage.

1. Refer to “Specification” on page 7-1 of this manual for

information on weight and dimensions.
2. Use properly rated cables and slings for lifting.
3. Position machine for a level lift.
4. Lifting cables should have a long enough length to
prevent contact with the machine. Spreader bars may
be required. FG008073
NOTE: If spreader bars are used, be sure that cables Figure 8
are properly secured to them and that the angle
of the cables is factored into the lift strength.

Transportation OP000472
5-4
 OP000497

6Troubleshooting
Anytime that a malfunction occurs, take immediate corrective
action. Check for and investigate the cause of the malfunction. A
schedule maintenance program can prevent malfunctions from
occurring by doing preventative maintenance. A systematic
approach should be taken to troubleshooting, since several
overlapping malfunctions may give the appearance of a problem
that does not exist. If cause for the malfunction cannot be
determined, contact your DOOSAN distributor. Never perform an
adjustment of or disassembly of, hydraulic components,
electrical and electronic components, without first consulting a
DOOSAN distributor.

CONTROL VALVE
Problem Possible Cause Remedy
Fails to bear load. Leaky spool. Replace valve housing assembly relief
valve.
Leaky port relief valve. Disassemble, clean or replace port.

Load drops when control is Foreign material in load check Disassemble and clean load check valve.
moved from neutral to UP. valve.
Damaged poppet or seal in load Replace poppet or lap poppet and seal.
check valve.
Spool sticking. Hydraulic oil excessively hot due to Remove blockage.
blockage.
Hydraulic oil fouled. Change oil and clean oil passages.

Valve housing deformed due to Replace valve housing.

overtightened fittings on hydraulic
oil line.
Spool does not move. Foreign material in valve. Clean valve.

Spool cap fouled with oil. Replace cap shaft seal.

Leaky spool. Replace valve housing assembly.

Troubleshooting OP000497
6-1
 Problem Possible Cause Remedy
Leaky oil seal. Foreign material in spool. Clean or replace valve housing assembly.

Pressure too high. Check with pressure gauge and adjust.

Lever or linkage bent. Remove and check linkage.

Return spring damaged. Replace.

Valve temperature uneven. Warm up entire system.

Foreign material in seal. Clean seal.

High back pressure in valve return Increase size of return line.

line.
Foreign material in seal. Clean seal.

Damaged spool. Replace valve housing assembly.

Seal cracked or damaged. Replace.

RELIEF VALVE
Problem Possible Cause Remedy
Pressure does not rise. Poppet sticking open. Disassemble and clean.

Pressure unstable. Damaged pilot poppet seal. Replace damaged parts.

Main poppet of pilot piston sticking. Disassemble, clean and remove surface
pitting.
Abrupt rise and fall in Wear, due to foreign material. Replace worn parts.
pressure.
Locknut and adjusting spring loose. Adjust pressure.

Oil leaks. Seals leaking, O-ring worn. Replace worn or damaged parts.

Parts sticking, due to foreign Disassemble, check for damage and

material. clean.

CENTER JOINT
Problem Possible Cause Remedy
Lack of power Bad center joint seal. Replace.

Damaged center joint rotor. Replace.

Bad seal. Replace seal.

Troubleshooting OP000497
6-2
CONTROL LEVER
Problem Possible Cause Remedy
Lever feels "heavy" when Foreign material in control valve Clean control valve.
operated. spool.
Valve spool sticking. Replace valve housing assembly.

Lack of linkage lubrication. Lubricate.

ATTACHMENTS
Problem Possible Cause Remedy
Lack of power. Lack of engine power.

Poor performance due to worn Replace hydraulic pump.

hydraulic pump.
Bad main relief valve. Adjust pressure or replace.

Low level of hydraulic oil. Add oil.

Wrong viscosity hydraulic oil. Replace with correct viscosity.

Suction filter restricted. Replace filter.

Poor overall performance. Hydraulic pump failure. Replace hydraulic pump.

Hydraulic oil level low. Add oil.

Lack of power. Main or port relief valve pressure Adjust pressure.

set too low.
Damaged hydraulic cylinder seal. Replace seal.

Hydraulic cylinder piston or rod Replace piston or rod.

damaged.
Unusual sound from Lack of grease. Add grease.
attachment connections.
Coupling pin worn. Replace bushing or pin.

Troubleshooting OP000497
6-3
HYDRAULIC MOTOR
Problem Possible Cause Remedy
Hydraulic motor does not Hydraulic oil low. Add oil.
rotate.
Hydraulic pump bad. Replace pump.

Oil leak from inside hydraulic Replace motor.

motor.
Overload applied to output shaft. Locate and remove cause of overload.

Low viscosity hydraulic oil. Change to oil with correct viscosity.

Hydraulic motor will not Bad control valve relief valve. Clean or replace relief valve.
allow turning to one side.
Counterbalance valve spool Replace counterbalance valve.
sticking.
RPM low. Main or port relief valve pressure Add oil.
set too low.
Oil leak due to excessive high Reduce oil temperature.
temperature.
Air in system. Bleed.

Oil leak from inside motor. Replace motor.

Unusual sound from Hydraulic oil level low. Add oil.

hydraulic motor.
Air in motor. Retighten fittings on suction side.

Wear and damage inside hydraulic Replace motor.

motor.
Shaft not properly installed. Readjust shaft.

HYDRAULIC CYLINDER
Problem Possible Cause Remedy
Lack of cylinder power. Relief valve pressure set too low. Adjust pressure.

Oil leak from inside cylinder. Replace cylinder seals.

Cylinder piston or rod damaged. Replace piston or rod.

Oil leak from inside control valve. Replace valve housing assembly.

Oil leak from outside Bad hydraulic cylinder seals. Replace seals.
cylinder.
Damaged cylinder rod. Replace rod.

Unsmooth piston Hydraulic oil temperature high. Lower temperature.

movement.
Air in system. Retighten fittings on oil fill and suction
sides.

Troubleshooting OP000497
6-4
HYDRAULIC PUMP
Problem Possible Cause Remedy
Poor oil delivery. Hydraulic oil level low. Add oil.

Suction filter restricted. Clean or replace filter.

Pressure does not rise. Oil leak from inside pump. Replace pump.

Air in pump. Add oil or check suction side hose.

Main relief valve pressure set too Adjust pressure.

low.
Unusual sound from Cavitation from bent suction side Replace hose and filter.
hydraulic pump. hose or clogged suction filter.
Cavitation from suction side fittings Tighten fittings and add oil.
and air in system due to low oil
level.
Cavitation due to high viscosity oil. Replace oil.

Pump and engine not aligned. Readjust shaft.

Air in hydraulic oil. Bleed.

Oil leak from outside pump. Bad hydraulic pump seal. Replace seal or pump.

SWING SYSTEM
Problem Possible Cause Remedy
Swing power weak. Hydraulic motor performs poorly. Replace hydraulic motor.

Swing bearing seized. Grease or replace swivel bearing.

Braking power weak. Brake valve pressure set low. Adjust pressure.

Foreign material in port relief or Clean valves.

brake valves.
Swing motion drags while Port relief or brake valve pressure Adjust pressure.
stopping. set low.
Foreign material in port relief or Clean valves.
brake valves.
Unusual sound. Air in system. Add oil.

Swing bearing needs grease. Grease.

Troubleshooting OP000497
6-5
TRAVEL
Problem Possible Cause Remedy
Lack of power when Main relief valve pressure set too Adjust pressure.
traveling. low.
Counterbalance valve bad. Replace counterbalance valve.

Hydraulic motor performs poorly. Replace hydraulic motor.

Damaged center joint seal. Replace seal.

Hydraulic pump bad. Replace hydraulic pump.

Oil leak from inside control valve. Replace valve housing assembly.

Travel not smooth. Tracks tension low. Adjust tension.

Stone(s) jammed in track. Remove.

Counterbalance valve bad. Replace valve.

Hydraulic motor performs poorly. Replace hydraulic motor.

Air in hydraulic motor. Add oil.

Machine wanders, does not Tracks have different tension. Adjust so tracks have equal tension.
travel straight.
Hydraulic pump performs poorly. Replace hydraulic pump.

Hydraulic motor performs poorly. Replace hydraulic motor.

Oil leak from inside control valve. Replace valve housing assembly.

Damaged center joint seal. Replace seal.

Lever linkage loose. Readjust linkage.

Troubleshooting OP000497
6-6
 OP000473

7Specification

STANDARD SPECIFICATION
SPECIFICATION
COMPONENT STANDARD 1.20m 1.33m
1.33m ARM
(1.20m ARM) ARM+Q/C ARM+Q/C
Bucket
SAE (CECE) 0.11 m3 (0.094 m3)
capacity
Operating weight 3.7 tons
Engine Model 3TNV88-SDB
Displacement
1,642 cc
(Total dis. Volume)
27.7 hp @ 2,200 rpm
Rated power
20.3 kW @2,200 rpm
Front Boom length 2,500 mm
Attachment Arm length (Standard) 1,250 mm
Arm length (Option) 1,330 mm
Transport Length 4,644 mm
Dimension Height 2,515 mm
Height (Boom) 1,720 mm
Width 1,700 mm
Performance Max.digging Bucket 3,010 kgf 2,380 kgf 3,010 kgf 2,380 kgf
force Arm 2,140 kgf 1,960 kgf 1,960 kgf 1,790 kgf
Traveling 1-speed 2.6 km/h
speed 2-speed 4.6 km/h
Swing speed 9.53 rpm
Drawbar pull 3,110 kg
Hydraulic Type Variable displacement axial piston pump
pump Max. flow rate 28.5 x 2 liters/min + 10.7 liters/min
(Gear pump: 5.1 liters/min)
Main relief set pressure 230 kg/cm2
Track Shoe width 300 mm
Tumbler distance 1,700 mm
Control Lever control type Hydraulic pilot
Lever pattern SAE
Tank Fuel tank 42 liters
Hydraulic tank 40 liters
Ground pressure 0.32 kg/cm 2

Specification OP000473
7-1
OVERALL DIMENSIONS

70
50
A
M B D
N C

O
P

E
Q

L
R

S H
T I
U
G

J
K
FG007625
Figure 1

Specification OP000473
7-2
 DIMENSION 2.405 M (7.89 FT) BOOM
A 4,644 mm (15' 3")
B 1,060 mm (3' 6")
C 850 mm (2' 9")
D 3,584 mm (11' 9")
E 1,720 mm (5' 8")
F 365 mm (1' 2")
G 407 mm (1' 4")
H 1,520 mm (4' 12")
I 1,700 mm (5' 7")
J 2,123 mm (6' 12")
K 2,580 mm (8' 6")
L 576 mm (1' 11")
M 1,500 mm (4' 11")
N 1,030 mm (3' 5")
O 1,015 mm ((3' 4")
P 2,515 mm (8' 3")
Q 310 mm (1' 0")
R 475 mm (1' 7")
S 300 mm (11.8 in)
T 1,400 mm (4' 7")
U 1,700 mm (5' 7")

Specification OP000473
7-3
WORKING RANGE

F
8

E
2
D

G.L 0
0 1 2 3 4 5 6 7 8

-1
B C

-2

-3

-4

-5

-6
A
FG007629
Figure 2

2.405 m (7.89 ft) BOOM

DIM.
1.2 m (3.9 ft) ARM 1.33 m (4.4 ft) ARM
A Max. digging radius 5,092 mm (16' 7") 5,201 mm (17' 1")
B Max. vertical digging depth 2,558 mm (8' 4") 2,627 mm (8' 6")
C Max. digging depth 3,023 mm (9' 9") 3,153 mm (10' 3")
D Max. dump height 3,391 mm (11' 1") 3,441 mm (11' 3")
E Max. digging height 4,887 mm (16' 0") 4,933 mm (16' 2")
F Min. digging radius 2,184 mm (7' 2") 2,040 mm (6' 7")

Specification OP000473
7-4
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.

LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR

DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
3 3
(1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD3), OR
LESS LESS LESS
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
433 kg/m3
Coke, blast furnace size --------------------- ---------------------
(729 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(756 lb/yd3)
801 kg/m3
Coal, bituminous slack, piled --------------------- ---------------------
(1,350 lb/yd3)
881 kg/m3
Coal, bituminous r. of m., piled --------------------- ---------------------
(1,485 lb/yd3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
1,009 kg/m3
Clay, DRY, in broken lumps --------------------- ---------------------
(1,701 lb/yd3)
1,746 kg/m3
Clay, DAMP, natural bed --------------------- ---------------------
(2,943 lb/yd3)
1,506 kg/m3
Cement, Portland, DRY granular --------------------- ---------------------
(2,583 lb/yd3)
1,362 kg/m3
Cement, Portland, DRY clinkers --------------------- ---------------------
(2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,202 kg/m3
Earth, loamy, DRY, loose --------------------- ---------------------
(2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy --------------------- ---------------------
(2,970 lb/yd3)

Specification OP000473
7-5
 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR
DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS
961 kg/m3
Gypsum, calcined, (heated, powder) --------------------- ---------------------
(1,620 lb/yd3)
1,522 kg/m3
Gypsum, crushed to 3 inch size --------------------- ---------------------
(2,565 lb/yd3)
1,810 kg/m3
Gravel, DRY, packed fragments --------------------- ---------------------
(3,051 lb/yd3)
1,922 kg/m3
Gravel, WET, packed fragments --------------------- ---------------------
(3,240 lb/yd3)
1,282 kg/m3
Limestone, graded above 2 --------------------- ---------------------
(2,160 lb/yd3)
Limestone, graded 1,362 kg/m3
--------------------- ---------------------
1-1/2 or 2 (2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulfur, broken --------------------- ---------------------
(1,620 lb/yd3)

Specification OP000473
7-6
 1Index
Numerics Radiator Coolant 4-33
1,000 Hour / 6 Month Service 4-31 Refill Cooling System 4-16
10 Hour / Daily Service 4-12 Cracks and Faulty Welds 4-18
12,000 Hour / Six Year Service 4-38 Cup Holder 2-29
2,000 Hour / Yearly Service 4-33 Cycle Time Tests 4-36
250 Hour / Monthly Service 4-23
4,000 Hour / Biennial Service 4-37 D
50 Hour / Weekly Service 4-20, 4-25 Description of Lubrication and Service Chart 4-8
500 Hour / 3 Month Service 4-29 Digital Clock 2-15
Door Side Latch 2-28
A
Adjust Valve Clearance 4-36 E
Air Intake System 4-18 Electrical System 4-47, 6-1
Outer Element of Air Cleaner 4-23 Engine 6-2
Replace Outer Air Cleaner Element 4-29 Adjust Valve Clearance 4-36
Alternator and Starter 4-35 Check Warning Light 2-17
Antifreeze Concentration Tables 4-53 Coolant Temperature Gauge 2-14
Antivibration Shock Mounts 4-35 Coolant Temperature Warning Light 2-17
Audio Control Panel 2-10 Emergency Stop Switch 2-10
Auxiliary Mode Switch 2-9 Fan Belt 4-25, 4-26
Head Bolt Torques 4-36
B Oil and Filter 4-22, 4-24
Batteries 4-28 Oil Level 4-12
Battery 4-47 Oil Pressure Warning Light 2-16
Electrolyte Level 4-48 Shutdown 3-11
Terminals 4-48 Speed Control Dial 2-8
Boom, Arm and Front Attachment Pins 4-20, 4- Start 3-4
21 Start and Stop 3-2
Booster Cable 3-7 Excavator Rated Lift Capacity Tables 1-49

C F
Cabin Light 2-20 Fan Belt 4-22
Cabin Storage Compartments 2-28 Front
Cabin Work Light Switch 2-11 Bottom Window 2-27
Charge Warning Light 2-16 End Attachments 4-28
Check and Confirmation After Stopping Engine 3- Upper Windows 2-26
12 Windows 2-26
Cold Weather Hydraulic System Warm-up 3-10 Fuel
Cold Weather Starting 3-6 Filter 4-30
Component Locations 2-2 Gauge 2-14
Coolant Temperature Warning Light 2-17 Level 4-15
Cooling System System 4-30
Engine 4-50 Tank Drain Valve 4-22
Engine Coolant Temperature Warning Light Fuse
2-17 Boxes 4-49

K1025196E Index
8-1
 Fuses 4-48 L
Fusible Link 2-20 Leaks in the Fuel System 4-15
Identification 4-49 Leaks in the Hydraulic System 4-14
Levers
G Adjusting the Seat Forward 2-24
Gauges Adjusting the Seat's Angle 2-24
Engine Coolant Temperature Gauge 2-14 Lifting 3-36
Fuel Gauge 2-14 Lifting With Sling 5-4
Hour Meter 2-16 Lights
Hydraulic Oil Temperature 2-15 Cabin 2-20
Multifunction Gauge 2-15 Loading and Unloading 5-1
General Venting 4-60 Locations of Safety Labels 1-5
Long Term Storage 4-55
Lubrication and filters 3-2
H
Lubrication and Service Chart 4-7
Handling a New Excavator 3-1
Handling of Accumulator 4-54
Hanger 2-29 M
Head Bolt Torques 4-36 Magnetic Clutch 4-39
Headlight Switch 2-11 Maintenance
Heater and Air Conditioner 2-21 In Special Conditions 4-47
Control Panel 2-22 Maintenance in Special Conditions 4-55
Location of Controls and Vents 2-21 Maintenance Intervals 4-10
System 4-39 Miscellaneous Access Doors 2-29
Hose Clamps 4-28 Multifunction Gauge 2-15
Hour Meter 2-16
Hydraulic System 6-2 N
General Venting 4-60 Nuts and Bolts 4-28
Hydraulic Breaker 3-29
Hydraulic Hoses and Tubing 3-29
O
Oil and Filter 3-32
Oil Level of Travel Reducer 4-27
Operation 3-30
Opening the Window 2-26
Selection 3-29
Operating
Hydraulic Cylinders 4-59
Controls 2-1
Hydraulic Oil Exchange 4-34
Instructions 3-19
Hydraulic Oil Return Filter 4-27, 4-31
Precautions 3-23
Hydraulic Oil Tank 4-13
Techniques 3-36
Hydraulic Oil Temperature Gauge 2-15
Operation 3-1
Leaks in the Hydraulic System 4-14
Operation In
Main System Pump 4-58, 4-59
Extreme Cold 3-38
Oil Exchange 4-34
Extreme Heat 3-39
Warm-up 3-9
High Altitudes 3-41
Rainy or Humid Conditions 3-41
I Salt Water Areas 3-41
Indicator Lights Operation of All Switches 4-18
Charge Warning Light 2-16 Operation Under Unusual Conditions 3-38
Coolant Temperature Warning Light 2-17 Operational Checks Before Starting Engine 3-3
Engine Check Warning 2-17 Operational Controls and Panels 2-6
Engine Oil Pressure Warning Light 2-16 Operator's Area 2-4
Inspecting Engine Before Starting 3-2 Operator's Compartment Light 2-20
Inspection, Maintenance and Adjustment 4-1 Outer Air Cleaner Element 4-29
Instrument Panel 2-12 Outer Element of Air Cleaner 4-23
Overall Dimensions 7-2

K1025196E Index
8-2
P Structural Damage 4-36
Panels Suction Strainer 4-34
Audio Control 2-10 Swing
Heater and Air Conditioner 2-21 Bearing 4-21
Heater and Air Conditioner Control Panel 2- System 6-3
22 Switches
Instrument Panel 2-12 Automatic Travel Speed Control 3-14
Parking Excavator 3-27 Auxiliary Mode 2-9
Pilot Cutoff Switch 2-20 Cabin Work Light Switch 2-11
Pins and Bushings 4-28 Engine Emergency Stop 2-10
Preliminary Work Machine Setup for Maintenance Engine Speed Control 3-19
4-3 Engine Speed Control Dial 2-8
Preventive Maintenance 4-1 Headlight Switch 2-11
Pilot Cutoff Switch 2-20
Quick Clamp (Optional) 2-9
Q
Starter Switch 2-8
Quick Clamp Switch (Optional) 2-9 Travel Speed Selector Switch 2-10
Warning Light 2-12
R
Radiator Coolant 4-33
T
Refill Cooling System 4-16
Table of Recommended Lubricants 4-5
Towing Procedure 3-28
S Track Assemblies 4-22
Safety 1-1 Travel 3-14
Safety Lever 3-13 Control Lever Operation 3-15
Safety Precautions 4-2 Instructions 3-16
Seat 2-24 Reduction Device 4-27, 4-32
Seat Adjustment Speed Selector Switch 2-10
Adjusting the Seat Forward 2-24 System 6-3, 6-4, 6-5, 6-6
Adjusting the Seat's Angle 2-24
Seat Belt 2-24, 4-18
U
Serial Numbers 4-2
Unloading and Loading 5-1
Shutdown
Check and Confirmation After Stopping
Engine 3-12 V
Engine Shutdown 3-11 Venting and Priming Hydraulic System 4-55
Parking Excavator 3-27 General Venting 4-60
Specification 7-1 Hydraulic Cylinders 4-59
Standard Specification 7-1 Main System Pump 4-58, 4-59
Starter Switch 2-8
Starting Engine Using a Booster Battery 3-7 W
Start-up Warning Light Switch 2-12
Cold Weather Hydraulic System Warm-up 3- Water Separator 4-16
10 Weight of Workload Materials 7-5
Cold Weather Starting 3-6 Window Washer Liquid 4-17
Engine Start 3-4 Windows
Hydraulic System Warm-up 3-9 Front 2-26
Inspection Before Starting Engine 3-2 Front Bottom 2-27
Operational Checks Before Starting Engine 3- Front Upper 2-26
3 Opening 2-26
Starting Engine Using a Booster Battery 3-7 Work Levers (Joysticks) (ISO Style) 3-19
Stereo 2-18 Working Range 7-4
Audio Control Panel 2-10

K1025196E Index
8-3