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Doosan DX300LL-3 Excavator Forestry Machine Operation & Maintenance Manual 950106-01178 – PDF DOWNLOAD
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Doosan DX300LL-3 Excavator Forestry Machine Operation & Maintenance Manual 950106-01178 – PDF DOWNLOAD
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950106-01178
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Description
Doosan DX300LL-3 Excavator Forestry Machine Operation & Maintenance Manual 950106-01178 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX300LL-3 Excavator Forestry Machine Operation & Maintenance Manual 950106-01178 – PDF DOWNLOAD
Serial Number 10001 and Up
950106-01178
Foreword
- This Operation & Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT.
- Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment.
- Any modification made without written authorization or approval from DOOSAN can create a safety hazard. Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.
Intended Use:
- The machine is intended to be used under normal conditions for applications described in this manual. If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use.
- Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual. Contact your DOOSAN distributor for further information.
Engine and Emission Control System Maintenance
- Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating. This includes proper inspection and maintenance of the machine’s emission control system.
- This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and/or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance.
- The required maintenance procedures are outlined in this Operation & Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system.
TABLE OF CONTENTS:
Doosan DX300LL-3 Excavator Forestry Machine Operation & Maintenance Manual 950106-01178 – PDF DOWNLOAD
DX300LL-3....................................................................................................................... 0 Table of Contents........................................................................................................... 5 Foreword.................................................................................................................... 9 Intended Use............................................................................................................ 9 Engine and Emission Control System Maintenance.......................................................................... 9 Safety Messages......................................................................................................... 12 AEM Safety Manual (North America Only).................................................................................. 13 Federal Emission Control Systems........................................................................................ 14 Limited Warranty for Non-road Engines (CI).......................................................................... 14 Owner’s Warranty Rights and Obligations............................................................................. 14 Manufacturer’s Warranty Coverage.................................................................................... 15 Owner’s Warranty Responsibilities................................................................................... 15 Safety...................................................................................................................... 17 Safety Decals........................................................................................................... 18 Safety Decals With Text............................................................................................. 18 Safety Decals Without Text (No-Text)................................................................................ 19 Information and Location for Safety Decals.......................................................................... 20 Information and Location for Safety Decals (Continued).............................................................. 21 General................................................................................................................. 31 Safe Operation is Operator's Responsibility......................................................................... 31 Know Your Machine................................................................................................... 31 Proper Work Tools and Attachments................................................................................... 32 Pressurized Fluids.................................................................................................. 32 Flying or Falling Objects........................................................................................... 33 Personal Protective Equipment (PPE)................................................................................. 34 Correction of Machine Problems...................................................................................... 34 Crushing and Cutting................................................................................................ 34 Hot Coolant and Oils - Burn Prevention.............................................................................. 35 Fire and Explosion Prevention....................................................................................... 36 Maintenance..................................................................................................... 36 Operation....................................................................................................... 36 Electrical...................................................................................................... 37 Hydraulic System................................................................................................ 37 Fueling......................................................................................................... 38 Never Use Ether Starting Aids................................................................................... 38 Welding and Grinding............................................................................................ 38 If a Fire Occurs................................................................................................ 39 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)......................................................... 39 Electrical System and Electrical Shock.............................................................................. 40 Protecting Cabin from Flying or Falling Objects (Optional)...................................................... 40 Emergency Exit from Operator's Station.......................................................................... 41 Transportation.......................................................................................................... 42 Obey State and Local Over-the-Road Regulations...................................................................... 42 Loading and Unloading............................................................................................... 42 Transporting Machine................................................................................................ 43 Operation............................................................................................................... 44 Before Engine Starting.............................................................................................. 44 Machine Condition............................................................................................... 44 Work Site........................................................................................................... 45 Mounting/Dismounting................................................................................................ 46 Cleaning............................................................................................................ 47 Operator Station.................................................................................................... 47 Seat Belt........................................................................................................... 48 Visibility Information.............................................................................................. 49 Work Site Rules................................................................................................. 50 Boost Starting or Charging Engine Batteries......................................................................... 50 Starting Engine..................................................................................................... 51 Swinging or Traveling............................................................................................... 52 Lifting and Logging................................................................................................. 54 Operation on Slopes................................................................................................. 55 Towing.............................................................................................................. 56 Attachment.......................................................................................................... 57 Equipment Lowering with Engine Stopped.............................................................................. 57 Preservation/Storing Machine........................................................................................ 59 Check After Long-term Parking................................................................................... 60 Maintenance............................................................................................................. 61 Cleaning............................................................................................................ 64 Proper Tools and Clothing........................................................................................... 64 Disassembling Precautions........................................................................................... 64 Use of Lighting..................................................................................................... 65 Fire and Explosion Prevention....................................................................................... 65 Burn Prevention..................................................................................................... 66 Rubber That Contains Fluorides...................................................................................... 67 Rubber and Plastics................................................................................................. 68 Waste Hazardous to the Environment.............................................................................. 68 Check List After Fire........................................................................................... 68 Welding Repairs..................................................................................................... 69 Preparation for Electrical Welding On Body Structure............................................................ 70 Warning for Counterweight and Front Attachment Removal.............................................................. 70 Lock Inspection Covers.............................................................................................. 71 Working on Machine.................................................................................................. 71 Accumulator......................................................................................................... 72 Compressed Air...................................................................................................... 72 Track Tension Adjustments........................................................................................... 73 Supports and Blocking for Work Equipment............................................................................ 73 High-pressure Lines, Tubes and Hoses................................................................................ 74 Battery............................................................................................................. 75 Battery Hazard Prevention....................................................................................... 75 Environment and Circumstances........................................................................................... 77 Work Site Areas Requiring Extra Caution............................................................................. 77 Digging Under an Overhang....................................................................................... 77 Deep Digging.................................................................................................... 77 Drop-off or Edge................................................................................................ 78 Poor Visibility................................................................................................. 78 Loose or Soft Ground............................................................................................ 78 High-voltage Cables................................................................................................. 79 Underground Operation............................................................................................... 80 Working in Water.................................................................................................... 80 Working in Contaminated Environment................................................................................. 80 Operation in Extreme Conditions..................................................................................... 81 Operation In Extreme Cold....................................................................................... 81 Operation in Extreme Heat....................................................................................... 82 Operation In Dusty and Sandy Areas.............................................................................. 83 Operation in Rainy or Humid Conditions.......................................................................... 84 Operation in Saltwater Areas.................................................................................... 84 Operation at High Altitudes..................................................................................... 84 Operation During Electrical Storms.............................................................................. 85 Exhaust Ventilation................................................................................................. 85 Ventilation for Enclosed Area................................................................................... 85 Asbestos Information................................................................................................ 86 Silica Dust Information............................................................................................. 86 Disposal of Hazardous Materials..................................................................................... 87 Vibration........................................................................................................... 88 Operating Controls.......................................................................................................... 89 Component Locations..................................................................................................... 90 Operator's Area......................................................................................................... 92 Operational Controls and Panels......................................................................................... 94 1. Starter Switch................................................................................................... 96 2. Heater and Air Conditioner Control Panel......................................................................... 96 3. Power Socket for 12 Volt......................................................................................... 97 4. Cigarette Lighter................................................................................................ 97 5. Engine Emergency Stop Switch..................................................................................... 97 6. Engine Speed Control Dial........................................................................................ 98 7. Travel Speed Selector Switch..................................................................................... 98 8. Light Switch..................................................................................................... 98 9. Cabin Work Light Switch.......................................................................................... 99 10. Audio Control Panel............................................................................................. 99 11. Wiper Control Panel.............................................................................................100 12. Warning Light Switch (Optional).................................................................................101 13. Travel/Swing Alarm Switch.......................................................................................102 14. 2-Pump Flow Control Switch......................................................................................102 15. Power Socket for 12 Volt (Optional).............................................................................102 16. Horn Button (Left-hand Work Lever)..............................................................................103 17. Breaker / Booster Button (Right-hand Work Lever)................................................................103 18. Rotating Switch.................................................................................................103 19. Shear Switch....................................................................................................104 20. Display Monitor.................................................................................................104 21. Photo Sensor....................................................................................................104 22. Safety Lever....................................................................................................105 23. Auxiliary Mode Switch...........................................................................................105 24. Hour Meter......................................................................................................105 25. Diesel Particulate Filter (DPF) Switch..........................................................................106 26. One Touch Deceleration Button...................................................................................106 27. Jog Switch Control Panel........................................................................................107 28. Jack Assembly...................................................................................................109 Display Monitor.........................................................................................................110 Functional Check....................................................................................................110 Password Activated..................................................................................................111 1. Fuel Gauge.......................................................................................................111 2. Engine Coolant Temperature Gauge.................................................................................111 3. Hydraulic Oil Temperature Gauge..................................................................................112 4. Multifunction Gauge and Graphic Information Area.................................................................112 5. ECO Gauge........................................................................................................114 6. Digital Clock....................................................................................................114 7. Display Warning Symbols..........................................................................................115 9. Function Buttons.................................................................................................122 10. Mode Selector Buttons...........................................................................................124 11. Selector Function Display.......................................................................................125 12. Jog Switch......................................................................................................125 13. Camera Mode Selector/ESC Button.................................................................................125 14. Multimedia Selector Button......................................................................................126 Warning Pop-up Window...............................................................................................126 User Menu............................................................................................................... 0 Switch Operation Indication.........................................................................................153 Heater and Air Conditioner Control Panel................................................................................156 Location of Controls and Vents......................................................................................156 Control Panel.......................................................................................................157 Memory Function.....................................................................................................161 Additional Operating Instructions...................................................................................161 Miscellaneous Electrical Devices........................................................................................163 Cabin Light.........................................................................................................163 Pilot Cutoff Switch.................................................................................................163 Circuit Breaker.....................................................................................................163 Fusible Link........................................................................................................164 Fuse Boxes..........................................................................................................164 Seat Adjustment......................................................................................................... 0 7. Storage Compartment..............................................................................................167 8. Left and Right Control Stand Adjustment..........................................................................167 Tilt Cabin..............................................................................................................173 Cabin Storage Compartments..............................................................................................174 Sunglass Case...........................................................................................................174 Miscellaneous Access Covers and Doors...................................................................................177 Side Door...........................................................................................................177 Battery Box Door....................................................................................................177 Engine Cover........................................................................................................177 Operation...................................................................................................................179 To Operate a New Forestry machine.......................................................................................179 Lubrication and Filters.............................................................................................180 Starting and Stopping Engine............................................................................................180 Inspection Before Starting Engine...................................................................................180 Walk Around Checks..............................................................................................180 Checks Before Starting Engine...................................................................................181 Operational Checks Before Starting Engine...........................................................................182 Engine Start........................................................................................................183 Cold Weather Starting...............................................................................................185 Starting Engine With a Booster Cable................................................................................186 Connecting Booster Batteries....................................................................................187 Disconnecting Booster Batteries.................................................................................187 Hydraulic System Warm-up............................................................................................188 Hydraulic System Warm-up - Cold Weather.............................................................................189 Stopping Engine.....................................................................................................190 Checks and Maintenance After Stopping Engine........................................................................191 Safety Lever............................................................................................................192 Travel..................................................................................................................193 Automatic Travel Speed Control......................................................................................193 Travel Control Lever Operation......................................................................................194 General Travel Instructions.........................................................................................195 Operating Instructions..................................................................................................198 Engine Speed Control................................................................................................198 Engine Exhaust Emission Control System..............................................................................198 Regeneration of Diesel Particulate Filter (DPF).................................................................199 Diesel Particulate Filter (DPF) Regeneration Light and Switch...................................................199 Passive Regeneration............................................................................................202 Active Regeneration.............................................................................................202 Manual (Forced) Regeneration....................................................................................203 DPF Cleaning (Removing Ash in DPF)..............................................................................205 Removal and Installation of the DPF Assembly....................................................................205 Mode Selection......................................................................................................206 Power Mode......................................................................................................206 Work Mode.......................................................................................................207 Auto Idle Mode..................................................................................................207 Boost Mode......................................................................................................208 Work Levers (Joysticks) (ISO Pattern)...............................................................................209 Left-hand Work Lever (Joystick) (Figure 57 and Figure 58).......................................................209 Right-hand Work Lever (Joystick) (Figure 57 and Figure 60)......................................................209 Operating Precautions...................................................................................................210 Always Observe These Precautions....................................................................................212 Working in Water....................................................................................................213 Escaping From Mud...................................................................................................213 Track On One Side Stuck.........................................................................................213 Tracks On Both Sides Stuck......................................................................................213 Towing Procedure........................................................................................................215 Operation Under Abnormal Conditions.....................................................................................216 Operation in Extreme Cold...........................................................................................216 Operation in Extreme Heat...........................................................................................217 Operation in Dusty and Sandy Areas..................................................................................219 Operation in Rainy or Humid Conditions..............................................................................219 Operation in Saltwater Areas........................................................................................220 Operation at High Altitudes.........................................................................................220 Operation During Electrical Storms..................................................................................220 Equipment Lowering with Engine Stopped..............................................................................221 Machine without a Boom Lowering Control Valve...................................................................221 Machine with a Boom Lowering Control Valve......................................................................223 Long Term Storage.......................................................................................................224 Before Storage......................................................................................................224 During Storage......................................................................................................225 After Storage.......................................................................................................225 Inspection, Maintenance and Adjustment......................................................................................227 Maintenance Information.................................................................................................227 Operational Hour Meter Reading......................................................................................227 DOOSAN Genuine Replacement Parts....................................................................................227 DOOSAN Genuine Lubricants...........................................................................................227 Windshield Washer Fluid.............................................................................................227 Fresh and Clean Lubricants..........................................................................................227 Check Drained Oil and Used Filter...................................................................................228 Fuel Strainer.......................................................................................................228 Welding Instructions................................................................................................228 Do Not Drop Things Inside Machine...................................................................................228 Dusty Work Site.....................................................................................................228 Avoid Mixing Lubricants.............................................................................................229 Locking Inspection Covers...........................................................................................229 Hydraulic System - Air Bleeding.....................................................................................229 Hydraulic Hose Installation.........................................................................................229 Checks After Inspection and Maintenance Works.......................................................................229 Safety Precautions..................................................................................................230 Machine Setup Position for Maintenance..................................................................................231 Maintenance Handling Access.............................................................................................233 Entering/Leaving/Climbing On Machine................................................................................233 Handling Oil, Fuel, Coolant.............................................................................................234 Oil.................................................................................................................234 Fuel................................................................................................................234 Engine Oil..........................................................................................................236 Grease..............................................................................................................236 Coolant and Water for Dilution......................................................................................237 Filters.............................................................................................................238 Electrical System Maintenance...........................................................................................239 Recommend Fuel, Coolant, and Lubricant..................................................................................240 Lubrication.........................................................................................................240 Symbols for "Lubrication and Service Chart".........................................................................241 Fluid Capacities........................................................................................................244 Table of Recommended Lubricants.........................................................................................245 Maintenance Intervals...................................................................................................247 10 Hour / Daily Service.................................................................................................250 Grease Boom, Arm and Front Attachment Pins (for first 100 hours)....................................................250 Check Engine Oil Level..............................................................................................250 Check Level of Hydraulic Oil Tank...................................................................................251 Check for Leaks in Hydraulic System.................................................................................252 Check Fuel Level....................................................................................................253 Check for Leaks in Fuel System......................................................................................254 Check Fuel Prefilter and Drain Water As Required....................................................................254 Check Oil Level of Swing Reduction Device...........................................................................255 Clean Dust Net in Front of Oil Cooler and Radiator..................................................................256 Oil Cooler......................................................................................................256 Radiator........................................................................................................256 Check Cooling System and Refill As Required.........................................................................257 Check Level of Window Washer Liquid.................................................................................257 Inspect Cooling Fan Blade...........................................................................................258 Check Air Intake System and Emission Control System Components......................................................258 Inspect Seat Belt for Proper Operation..............................................................................259 Inspect Rear View Camera for Proper Operation (If Equipped).........................................................259 Inspect Mirrors for Damage and Adjust and Clean as Required.........................................................259 Inspect Structure for Cracks and Faulty Welds.......................................................................259 Check Operation of All Switches and Travel Alarm (If Equipped)......................................................259 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor......................259 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature.....260 Check Operation of All Controls and Linkages........................................................................260 50 Hour / Weekly Service................................................................................................261 Perform All Daily Service Checks....................................................................................261 Grease Arm and Heel Joint Pins......................................................................................261 Grease Swing Bearing................................................................................................265 Drain Water and Sediment from Fuel Tank.............................................................................265 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)...................................266 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)....266 250 Hour / Monthly Service.............................................................................................. 0 Check Engine Fan and Alternator Belts Wear..........................................................................268 Replace Hydraulic Oil Return Filter (After First 250 Hours).........................................................269 Change Pilot Filter (After First 250 Hours).........................................................................269 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear............................................269 Check Fluid Levels in Batteries.....................................................................................269 Inspect for Any Loose or Missing Nuts and Bolts.....................................................................269 Inspect Fuel System Hose Clamps.....................................................................................269 500 Hour / 3 Month Service..............................................................................................270 Perform All Daily, 50 and 250 Hour Service Checks...................................................................270 Grease Swing Gear and Pinion........................................................................................270 Change Engine Oil and Filter........................................................................................271 Clean Air-conditioning Outer Filter.................................................................................272 Check and Clean Air-conditioning Inner Filter.......................................................................273 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores............................274 Clean Outer Filter of Air Cleaner...................................................................................275 Change of Fuel Prefilter............................................................................................277 Change Fuel Filter..................................................................................................278 Fuel System Priming.............................................................................................278 Check Oil Level in Travel Reduction Device (One on Each Side of Unit)...............................................279 Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)............................279 Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)..........................................279 1,000 Hour / 6 Month Service............................................................................................280 Perform All Daily, 50, 250 and 500 Hour Service Checks..............................................................280 Grease Swing Reduction Device.......................................................................................280 Change Pilot Filter.................................................................................................282 Change Oil in Travel Reduction Device (One on Each Side of Unit)....................................................283 Change Swing Reduction Device Oil...................................................................................284 Change Hydraulic Oil Tank Breather Filter...........................................................................285 Change Air-conditioning Outer Filter................................................................................286 Check Air Conditioner Refrigerant...................................................................................287 Check and Adjust Engine**...........................................................................................287 Change Fuel Cap Filter..............................................................................................288 2,000 Hour / Yearly Service............................................................................................. 0 Change Radiator Coolant.............................................................................................292 Hydraulic Oil Exchange and Suction Strainer Cleaning................................................................294 Check Alternator and Starter**......................................................................................296 Check All Rubber Antivibration Shock Mounts.........................................................................296 Perform and Record Results of Cycle Time Tests......................................................................296 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.....................................296 Check, Adjust Valve Clearance**.....................................................................................296 Check Head Bolt Torques.............................................................................................296 4,000 Hour / Biennial Service...........................................................................................297 Major Parts - Periodic Replacement..................................................................................297 4,500 Hour / Biennial Service...........................................................................................298 Clean Diesel Particulate Filter (DPF)...............................................................................298 12,000 Hour / 6 Year Service............................................................................................299 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN)).........................................299 Air-conditioning System.................................................................................................300 Check Control Panel.................................................................................................300 Check Air Conditioner Hoses.........................................................................................300 Check Condenser.....................................................................................................300 Check Magnetic Clutch...............................................................................................300 Check Belt Tension..................................................................................................300 Bolt and Nut Inspection.................................................................................................301 Electrical System.......................................................................................................309 Battery.............................................................................................................309 Batteries in Cold Weather.......................................................................................309 Inspection of Battery Electrolyte Level.........................................................................310 Check Charging State............................................................................................310 Check Battery Terminals.........................................................................................310 Battery Replacement.............................................................................................310 Fuses...............................................................................................................311 Fuse Boxes......................................................................................................311 Fuse Identification.............................................................................................312 Engine Cooling System...................................................................................................313 General.............................................................................................................313 Types of Antifreeze.............................................................................................314 Antifreeze Concentration Tables.....................................................................................315 Table of Standards for Allowed Tap Water............................................................................315 Handling of Accumulator.................................................................................................316 Track Tension...........................................................................................................317 Venting and Priming Hydraulic System....................................................................................319 Main System Pump....................................................................................................319 Hydraulic Cylinders.................................................................................................319 Swing Motor.........................................................................................................320 Travel Motor........................................................................................................320 General Venting.....................................................................................................320 Maintenance in Special Conditions.......................................................................................321 Transportation..............................................................................................................323 Loading and Unloading...................................................................................................323 Warning for Counterweight and Front Attachment Removal..............................................................323 Troubleshooting.............................................................................................................331 Electrical System.......................................................................................................331 Engine..................................................................................................................332 Variable Geometry turbocharger (VGT)....................................................................................336 Lubrication System......................................................................................................337 Hydraulic System........................................................................................................338 Swing System............................................................................................................339 Travel System...........................................................................................................339 Hydraulic Fan Drive System..............................................................................................340 Specification...............................................................................................................341 Standard Specification..................................................................................................341 Overall Dimensions......................................................................................................342 Ground Pressure.........................................................................................................344 Working Range...........................................................................................................345 Forestry Machine Rated Lift Capacity Tables.............................................................................346 Approximate Weight of Workload Materials................................................................................349 Index.......................................................................................................................351
DOOSAN DX300LL-3 EXCAVATOR FORESTRY MACHINE OPERATION & MAINTENANCE MANUAL 950106-01178 – PDF DOWNLOAD:
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