DAEWOO DOOSAN DX140W DX160W Operation and Maintenance Manual

Copyright Doosan 2006 K1024898E Operation and Maintenance Manual DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Operation and Maintenance Manual K1024898E Serial Number 5001 and Up September 2006 DX140W/DX160W

K1024898E I Table of Contents 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 ..................................................................... 1-23 Machine Operation........................................................................... 1-27 Maintenance .................................................................................... 1-33 Battery ............................................................................................. 1-41 Towing .............................................................................................. 1-43 Shipping and Transportation ............................................................ 1-44 Excavator Rated Lift Capacity Tables............................................... 1-45 Operating Controls ....................................................................2-1 Component Locations ........................................................................ 2-4 Operator's Area .................................................................................. 2-6 Operational Controls and Panels ....................................................... 2-8 Instrument Panel .............................................................................. 2-26 Multifunction Gauge and Graphic Information ................................. 2-32 Mode Selector Buttons..................................................................... 2-38 Setting Main Menu ........................................................................... 2-40 Flow Control ..................................................................................... 2-49 Operation Selection Display ............................................................. 2-51 Heater and Air Conditioner Control Panel ........................................ 2-53 Stereo .............................................................................................. 2-60 Miscellaneous Electrical Devices ..................................................... 2-62 Seat Adjustment............................................................................... 2-64

K1024898E Table of Contents II Ceiling Cover ................................................................................... 2-68 Front Windows ................................................................................. 2-69 Door Side Latch ............................................................................... 2-71 Cabin Storage Compartments ......................................................... 2-72 Ashtray ............................................................................................. 2-72 Sun Visor.......................................................................................... 2-73 Hanger ............................................................................................. 2-73 Cup Holder ....................................................................................... 2-74 Door Window Holder ........................................................................ 2-74 Emergency Glass Breaking Tool ...................................................... 2-74 Miscellaneous Access Covers and Doors ........................................ 2-75 Swing Lock Pin and Mechanism ...................................................... 2-77 Wheel Chocks .................................................................................. 2-77 Operation ....................................................................................3-1 To Handle a New Excavator ............................................................... 3-1 Starting and Stopping the Engine ...................................................... 3-2 Safety Lever ..................................................................................... 3-14 Travel ................................................................................................ 3-15 Operating Instructions ...................................................................... 3-23 Operating Precautions ..................................................................... 3-31 Parking Excavator ............................................................................ 3-36 Towing Procedure ............................................................................ 3-37 Hydraulic Breaker ............................................................................ 3-39 Adjusting the Pump Flow ................................................................. 3-44 Operating Techniques ...................................................................... 3-47 Operation Under Unusual Conditions .............................................. 3-49 Inspection, Maintenance and Adjustment ...............................4-1 Preventive Maintenance..................................................................... 4-1 Preliminary Work Machine Setup for Maintenance ............................ 4-4 Table of Recommended Lubricants ................................................... 4-6 Fluid Capacities ................................................................................. 4-8

K1024898E III Table of Contents Lubrication and Service Chart ........................................................... 4-8 Maintenance Intervals ...................................................................... 4-13 10 Hour / Daily Service .................................................................... 4-16 50 Hour / Weekly Service ................................................................ 4-26 250 Hour Service ............................................................................. 4-30 500 Hour / 3 Month Service ............................................................. 4-35 1,000 Hour / 6 Month Service .......................................................... 4-46 2,000 Hour / Yearly Service.............................................................. 4-53 4,000 Hour / Biennial Service .......................................................... 4-62 12,000 Hour / Six Year Service ........................................................ 4-63 Air-Conditioning System .................................................................. 4-64 Inspection of Bolt And Nut Tightening Elements .............................. 4-65 Bucket .............................................................................................. 4-72 Electrical System ............................................................................. 4-75 Engine Cooling System.................................................................... 4-79 Fuel Transfer Pump (Optional) ......................................................... 4-81 Handling of Accumulator .................................................................. 4-84 Tires and Wheels ............................................................................. 4-86 Venting and Priming Hydraulic System ............................................ 4-91 Maintenance in Special Conditions .................................................. 4-94 Long Term Storage........................................................................... 4-95 Transportation............................................................................5-1 Short Distance Self-powered Travel ................................................... 5-2 Trailer Loading/Unloading Procedures ............................................... 5-3 Troubleshooting .........................................................................6-1 Engine ................................................................................................ 6-1 Hydraulic System ............................................................................... 6-3 Swing System .................................................................................... 6-4 Electrical System ............................................................................... 6-4 Travel System..................................................................................... 6-5 Steering ............................................................................................. 6-6

K1024898E Table of Contents IV Brakes ................................................................................................ 6-7 Speciﬁcation ..............................................................................7-1 Speciﬁcation....................................................................................... 7-1 Overall Dimensions ............................................................................ 7-4 Working Range .................................................................................. 7-7 Index ...........................................................................................8-1

OP000421 1-1 Safety OP000421 1Safety TO THE OPERATOR OF A DOOSAN DAEWOO EXCAVATOR 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 1-23 6. “Machine Operation” on page 1-27 7. “Maintenance” on page 1-33 8. “Battery” on page 1-41 9. “Towing” on page 1-43 10. “Shipping and Transportation” on page 1-44 11. “Excavator Rated Lift Capacity Tables” on page 1-45 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.

OP000421 Safety 1-2 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 shipped. 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.

OP000421 1-3 Safety 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. 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. CAUTION! This word is used on safety messages and safety labels and indicates potential 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 of a hazardous situation that, if not avoided, could result in serious injury or death. It may also be used to alert against a 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 explode or detonate if handled or treated carelessly.

OP000421 Safety 1-4 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 some procedures, contact a DOOSAN distributor.

DAEWOO DOOSAN DX140W DX160W Operation and Maintenance Manual

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