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Doosan DX300LL-3 Excavator Log Loader Shop Manual Sn10001 & Up – PDF DOWNLOAD
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Doosan DX300LL-3 Excavator Log Loader Shop Manual Sn10001 & Up – PDF DOWNLOAD
Serial Number 10001 and Up
950106-01179E
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Description
Doosan DX300LL-3 Excavator Log Loader Shop Manual Sn10001 & Up – PDF DOWNLOAD
DESCRIPTION:
Doosan DX300LL-3 Excavator Log Loader Shop Manual Sn10001 & Up – PDF DOWNLOAD
Serial Number 10001 and Up
950106-01179E
GENERAL
Safe Operation is Operator’s Responsibility
- Only trained and authorized personnel should operate and maintain the machine. Follow all safety rules, regulations and instructions when operating or performing maintenance on machine.
- Do not operate machine if you are under the influence of drugs or alcohol. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate a machine.
- When working with other personnel on a work site, be sure that all personnel know nature of work and understand all hand signals that are to be used.
- Be sure that all guards and shields are installed in their proper location. Have guards and shields repaired or replaced immediately if damaged.
- Be sure that you understand the use and maintenance of all safety features such as safety lock lever and seat belt. Use them properly.
- Never remove, modify or disable any safety features. Always keep them in good operating condition.
- Always check for and know the location of underground and overhead utility lines before excavating.
- Failure to use and maintain safety features according to instructions in this manual, Safety Manual and Shop Manual can result in death or serious injury.
Know Your Machine
- Know how to operate your machine. Know the purpose of all controls, gauges, signals, indicators and monitor displays. Know the rated load capacity, speed range, braking and steering characteristics, turning radius and operating clearances.
- Keep in mind that rain, snow, ice, loose gravel, soft ground, slopes etc., can change operating capabilities of your machine.
TABLE OF CONTENTS:
Doosan DX300LL-3 Excavator Log Loader Shop Manual Sn10001 & Up – PDF DOWNLOAD
DX300LL-3 Forestry Machine........................................................................... 0 Table of Contents................................................................................ 7 Safety........................................................................................... 9 Forestry Machine Maintenance Safety SP003059................................................. 11 Safety Instructions...................................................................... 15 Applicable Models........................................................................ 15 Safety Messages.......................................................................... 16 General.................................................................................. 16 Safe Operation is Operator's Responsibility.......................................... 16 Know Your Machine.................................................................... 16 Proper Work Tools and Attachments.................................................... 17 Pressurized Fluids................................................................... 17 Flying or Falling Objects............................................................ 18 Personal Protective Equipment (PPE).................................................. 19 Correction of Machine Problems....................................................... 19 Crushing and Cutting................................................................. 19 Hot Coolant and Oils - Burn Prevention............................................... 20 Fire and Explosion Prevention........................................................ 21 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit).......................... 24 Electrical System and Electrical Shock............................................... 25 Transportation........................................................................... 27 Obey State and Local Over-the-Road Regulations....................................... 27 Loading and Unloading................................................................ 27 Transporting Machine................................................................. 28 Operation................................................................................ 29 Before Engine Starting............................................................... 29 Work Site............................................................................ 30 Mounting/Dismounting................................................................. 31 Cleaning............................................................................. 32 Operator Station..................................................................... 32 Seat Belt............................................................................ 33 Visibility Information............................................................... 34 Boost Starting or Charging Engine Batteries.......................................... 35 Starting Engine...................................................................... 36 Swinging or Traveling................................................................ 37 Lifting and Logging.................................................................. 39 Operation on Slopes.................................................................. 40 Towing............................................................................... 41 Attachment........................................................................... 42 Equipment Lowering with Engine Stopped............................................... 42 Preservation/Storing Machine......................................................... 44 Maintenance.............................................................................. 46 Cleaning............................................................................. 50 Proper Tools and Clothing............................................................ 50 Disassembling Precautions............................................................ 50 Use of Lighting...................................................................... 51 Fire and Explosion Prevention........................................................ 51 Burn Prevention...................................................................... 52 Rubber That Contains Fluorides....................................................... 53 Rubber and Plastics.................................................................. 54 Welding Repairs...................................................................... 55 Warning for Counterweight and Front Attachment Removal............................... 56 Lock Inspection Covers............................................................... 57 Working on Machine................................................................... 57 Accumulator.......................................................................... 58 Compressed Air....................................................................... 58 Track Tension Adjustments............................................................ 59 Supports and Blocking for Work Equipment............................................. 59 High-pressure Lines, Tubes and Hoses................................................. 60 Battery.............................................................................. 61 Environment and Circumstances............................................................ 63 Work Site Areas Requiring Extra Caution.............................................. 63 High-voltage Cables.................................................................. 65 Underground Operation................................................................ 66 Working in Water..................................................................... 66 Working in Contaminated Environment.................................................. 66 Operation in Extreme Conditions...................................................... 67 Exhaust Ventilation.................................................................. 71 Asbestos Information................................................................. 71 Silica Dust Information.............................................................. 72 Disposal of Hazardous Materials...................................................... 72 Vibration............................................................................ 73 Specifications................................................................................... 75 Specifications for DX300LL-3 SP003060........................................................ 77 Safety Instructions...................................................................... 81 Applicable Models........................................................................ 81 General Description...................................................................... 83 Component Locations...................................................................... 84 Overall Dimensions....................................................................... 86 Working Range............................................................................ 88 General Specifications................................................................... 89 Approximate Weight of Workload Materials................................................. 93 Performance Tests........................................................................ 95 Forestry machine Performance Measurements................................................ 96 Test Conditions...................................................................... 96 Travel Speed and Travel Motor Balance (Steering Deviation) Tests..................... 96 Swing Speed and Deceleration Force Test.............................................. 98 Cylinder Performance Tests........................................................... 99 General Maintenance..............................................................................101 General Maintenance Instructions SP002454....................................................103 Safety Instructions......................................................................107 Applicable Models........................................................................107 Welding Precautions and Instructions.....................................................108 Hydraulic System - General Precautions...................................................109 Maintenance Service and Repair Procedure.................................................111 General Precautions..................................................................111 Hydraulic System Cleanliness and Oil Leaks...............................................112 Maintenance Precautions for Hydraulic System Service.................................112 Oil Leakage Precautions..............................................................113 Cleaning and Inspection..................................................................114 General Instructions.................................................................114 Bearing Inspection...................................................................115 Standard Torques SP002404....................................................................123 Safety Instructions......................................................................127 Applicable Models........................................................................127 Torque Values for Standard Metric Fasteners..............................................128 Torque Values for Standard U.S. Fasteners................................................129 Type 8 Phosphate Coated Hardware.........................................................131 Torque Values for Hose Clamps............................................................132 ORFS Swivel Nut Recommended Torque.......................................................132 Torque Values for Split Flanges..........................................................133 Torque Wrench Extension Tools............................................................134 Torque Multiplication................................................................134 Other Uses for Torque Wrench Extension Tools.........................................135 Tightening Torque Specifications (Metric)............................................136 Upper Structure..................................................................................139 Cabin SP003061...............................................................................141 Safety Instructions......................................................................145 Applicable Models........................................................................145 Fuel Tank SP003063...........................................................................153 afety Instructions.......................................................................157 Applicable Models........................................................................157 General Description...................................................................... 0 Specifications.......................................................................159 Start-up Procedures......................................................................168 Swing Bearing SP003064.......................................................................169 Safety Instructions......................................................................173 Applicable Models........................................................................173 Swing Bearing Maintenance................................................................174 Operating Recommendation.............................................................174 Measuring Swing Bearing Axial Play...................................................174 Measuring Bearing Lateral Play.......................................................174 Swing Bearing Basic Operation........................................................175 Disassembly..........................................................................175 Assembly.............................................................................177 Lower Structure and Chassis......................................................................179 Track Assembly SP003065......................................................................181 Safety Instructions......................................................................185 Applicable Models........................................................................185 General Description......................................................................186 Track Tension............................................................................187 Cleaning and Inspection (Wear Limits and Tolerances).....................................189 Track Shoe...........................................................................190 Lower Roller.........................................................................192 Upper Roller.........................................................................193 Front Idler..........................................................................194 Track Shoes and Links....................................................................195 Track Removal........................................................................195 Track Installation...................................................................196 Front Idler..............................................................................198 Parts List...........................................................................198 Front Idler Disassembly..............................................................199 Front Idler Reassembly...............................................................200 Lower and Upper Roller...................................................................202 Parts List...........................................................................202 Lower and Upper Roller Removal.......................................................203 Lower and Upper Roller Disassembly...................................................203 Lower and Upper Roller Reassembly....................................................204 Lower and Upper Roller Installation..................................................205 Track Spring and Track Adjusting Cylinder................................................206 Parts List...........................................................................206 Engine and Drivetrain............................................................................209 Drive Coupling (Main Pump) SP003066..........................................................211 Safety Instructions......................................................................215 Applicable Models........................................................................215 Drive Coupling...........................................................................216 Special Tools............................................................................217 Drive Coupling Installation..............................................................218 Installation Procedure...............................................................220 Hydraulics.......................................................................................221 Hydraulic System Troubleshooting, Testing and Adjustment SP003081............................223 Safety Instructions......................................................................227 Applicable Models........................................................................227 Hydraulic System - General Notes.........................................................229 Hydraulic Schematic......................................................................230 General Notes........................................................................230 Operation of Working Components..........................................................232 Boom Operating Circuit...............................................................232 Boom Up Circuit......................................................................232 Boom Down Circuit....................................................................232 Stick Operating Circuit..............................................................233 Stick in Circuit.....................................................................233 Stick out Circuit....................................................................233 Heel Operating Circuit...............................................................234 Heel Rack in Circuit.................................................................234 Heel Rack out Circuit................................................................234 Swing Operating Circuit..............................................................235 Right Swing Operating Circuit........................................................235 Left Swing Operating Circuit.........................................................235 Swing Relief Valve and Makeup Valve..................................................235 Travel Operating Circuit.............................................................236 Forward Travel Circuit...............................................................236 Reverse Travel Circuit...............................................................236 Procedural Troubleshooting Baseline Recommendations......................................237 Initial Checks and Tests to Establish Operating Condition of the Forestry machine....237 Pilot Pressure...........................................................................239 Adjustment and Testing...............................................................239 Power Mode Valve.........................................................................240 Current Signal and Hydraulic Pressure Adjustments....................................240 Pressure Up Valve........................................................................241 Checks and Adjustments...............................................................241 Pump Input Power Control.................................................................243 Pump Regulator Adjustment............................................................243 Flow Meter and Flow Meter Kit Installation and Testing...................................246 Swing System Troubleshooting.............................................................248 Precautions/Initial Checks...........................................................248 Swing Relief Valve Checking and Adjustment...........................................249 Troubleshooting - Swing Gearbox..........................................................251 Troubleshooting - Hydraulic Problems.....................................................252 Troubleshooting - Control Valve..........................................................254 Troubleshooting - Travel Control Valve...................................................255 Troubleshooting - Joystick Control Valve.................................................256 Accumulator SP003068.........................................................................257 Safety Instructions......................................................................261 Applicable Models........................................................................261 General Description...................................................................... 0 Specifications.......................................................................264 Center Joint (Swivel) SP003085...............................................................265 Safety Instructions......................................................................269 Applicable Models........................................................................269 General Description......................................................................271 Parts List...........................................................................272 Troubleshooting, Testing and Adjustment..................................................273 Inspection...........................................................................273 Testing..............................................................................273 Disassembly..............................................................................274 Reassembly...............................................................................275 Cylinders SP002332...........................................................................277 Safety Instructions......................................................................281 Applicable Models........................................................................281 General Description......................................................................282 Theory of Operation..................................................................282 Disassembly..............................................................................298 Reassembly...............................................................................303 Swing Motor SP002327.........................................................................307 Safety Instructions......................................................................311 Applicable Models........................................................................311 General Description...................................................................... 0 Theory of Operation.................................................................. 0 Generation of Rotary Power.......................................................313 Operation of Relief Valve........................................................314 Operation of Parking Brake.......................................................314 Parts List...........................................................................316 Specifications.......................................................................318 Torques..............................................................................318 Tools and Materials......................................................................319 Tools................................................................................319 Troubleshooting, Testing and Adjustment..................................................320 General Precautions..................................................................320 How to Check Faults of Hydraulic Motor...............................................320 Troubleshooting......................................................................320 Disassembly..............................................................................322 General Cautions.....................................................................322 Disassembly..........................................................................322 Cleaning and Inspection (Wear Limits and Tolerances).....................................330 Reassembly...............................................................................331 General Cautions.....................................................................331 Assembly.............................................................................331 Assembly of Cylinder Block Assembly Subassembly......................................334 Assembly of Rear Cover Assembly Subassembly..........................................338 Air Pressure Test....................................................................344 Oil Leakage Check....................................................................344 Swing Reduction Gear SP003080................................................................347 Safety Precautions.......................................................................351 Applicable Models........................................................................351 General Description......................................................................353 Theory of Operation..................................................................353 Parts List...........................................................................354 Specifications.......................................................................355 Disassembly..............................................................................358 Cleaning and Inspection (Wear Limits and Tolerances).....................................366 Reassembly...............................................................................367 Shaft and S/R Bearing Heat-fit.......................................................367 Assembly of Carrier Subassemblies....................................................367 Cleaning Carrier.................................................................367 Cleaning Planet Gear.............................................................367 Assembly of No. 1 Carrier........................................................367 Assembly of No. 2 Carrier........................................................370 Assembly of Main Case................................................................373 Cleaning Casing and Other Parts..................................................373 Assembly of Shaft and Pinion.....................................................373 Assembly of Seal and Bearing.....................................................378 Assembly of Ring Gear............................................................382 Assembly of Carrier..............................................................384 Assembly of Motor....................................................................389 Add Gear Oil.....................................................................389 Assembly of Motor................................................................389 Supply of Grease.................................................................391 Installation.............................................................................393 Start-up Procedures......................................................................393 Travel Motor SP003071........................................................................395 Safety Instructions......................................................................399 Applicable Models........................................................................399 General Description......................................................................401 Theory of Operation..................................................................402 Hydraulic Motor..................................................................402 Operation of Reduction Gear......................................................408 Parts List...........................................................................410 Hydraulic Motor..................................................................410 Reduction Gear...................................................................412 Specifications.......................................................................413 Special Tools and Materials..............................................................414 Hydraulic Motor Part.................................................................414 Reduction Gear Part..................................................................415 Tightening Torque Chart..............................................................416 Troubleshooting, Testing and Adjustment..................................................417 General Precautions..................................................................417 Troubleshooting......................................................................417 Disassembly..............................................................................420 General Caution Matters..............................................................420 Reduction Gear Part..................................................................420 Hydraulic Motor Part.................................................................426 Disassembly of Main Body of Motor Section........................................426 Disassembly of Valve Casing Subassembly..........................................429 Disassembly of Cylinder Block Assembly...........................................430 Cleaning and Inspection (Wear Limits and Tolerances).....................................431 Maintenance Standard.................................................................431 Changing Standard of Hydraulic Motor Part........................................431 Parts Inspection and Inspection Standard of Reduction Gear.......................433 Reassembly...............................................................................434 General Caution Matters..............................................................434 Hydraulic Motor Part.................................................................434 Reassembling of Driveshaft Subassembly...........................................434 Assembly of Valve Casing Subassembly.............................................434 Assembly of Valve Casing Subassembly.............................................435 Assembly of Cylinder Subassembly.................................................437 Reduction Gear Part..............................................................442 Checkup after Assembly...............................................................450 Air Test for Reduction Gear......................................................450 Air Test for Motor...............................................................450 Performance Test.....................................................................450 If Test Equipment Is Available...................................................450 If on-site performance test is unavoidable as test equipment is not available....451 Installation.............................................................................452 Check................................................................................452 Piping...............................................................................452 Gear Oil.............................................................................452 Kind of Oil......................................................................452 Oil Drain........................................................................452 Oil Filling..........................................................................453 General Caution Matters..............................................................453 Main Pump SP003082...........................................................................455 Safety Instructions......................................................................459 Applicable Models........................................................................459 Axial Piston Pump........................................................................460 General Description..................................................................460 Special Tools and Materials..........................................................465 Troubleshooting, Testing and Adjustment..............................................467 Remove and Install Pump Device...........................................................469 Removal..............................................................................469 Disassembly..........................................................................469 Cleaning and Inspection (Wear Limits and Tolerances).................................472 Reassembly...........................................................................474 Installation.........................................................................476 Start-up Procedures..................................................................478 Regulator for Axial Piston Pump..........................................................479 General Description..................................................................479 Special Tools and Materials..........................................................490 Troubleshooting, Testing and Adjustment..............................................490 Preparation for Disassembly..........................................................493 Regulator Disassembly................................................................494 Regulator Reassembly.................................................................497 Counterweight SP003062.......................................................................501 Safety Instructions......................................................................505 Applicable Models........................................................................505 General..................................................................................506 Warning for Counterweight and Front Attachment Removal...............................506 Installation.............................................................................509 Main Control Valve SP002403..................................................................511 Safety Instructions......................................................................515 Applicable Models........................................................................515 General Description......................................................................516 Theory of Operation..................................................................516 Parts List...........................................................................544 Specifications.......................................................................549 Troubleshooting, Testing and Adjustment..................................................550 Troubleshooting......................................................................550 Adjustment of Valves.................................................................551 Removal..................................................................................553 Disassembly..............................................................................554 Cleaning and Inspection (Wear Limits and Tolerances).....................................563 Cleaning.............................................................................563 Inspection...........................................................................563 Reassembly...............................................................................564 Caution on Assembly..................................................................564 Sequence of Subassembly..............................................................565 Maintenance of Relief Valves.........................................................571 Installation.............................................................................574 Start-up Procedures......................................................................575 Remote Control Valve (Work Lever / Joystick) SP003083........................................577 Safety Instructions......................................................................581 Applicable Models........................................................................581 General Description......................................................................583 Theory of Operation..................................................................583 Parts List...........................................................................584 Specifications.......................................................................586 Torques..............................................................................586 Tools and Materials......................................................................586 Disassembly..............................................................................587 Reassembly...............................................................................591 Start-up Procedures......................................................................598 Pedal Valve (with Damper) SP003069...........................................................599 Safety Instructions......................................................................603 Applicable Models........................................................................603 General Description......................................................................605 Theory of Operation..................................................................605 Pressure Reducing Valve..............................................................606 Operating Theory of Damper Mechanism.................................................607 Causes of Faults and Measures............................................................608 Parts List...........................................................................610 Specification........................................................................612 Torques..............................................................................612 Disassembly..............................................................................616 Cleaning and Inspection (Wear Limits and Tolerances).....................................618 Reassembly...............................................................................619 Installation.............................................................................624 Start-up Procedures......................................................................627 Solenoid Valve Assembly SP003084.............................................................629 Safety Instructions......................................................................633 Applicable Models........................................................................633 Parts List...............................................................................634 Functions of 5-Solenoid Valve Assembly Package...........................................635 Functions of Solenoid Valve Assembly Package.........................................635 This solenoid valve assembly package have the following functions................635 Functions and Operations of Solenoid Valves......................................635 Detailed Functions and Operations of Solenoid Valves.............................635 Assembly Diagram and Tools Required..................................................637 Cautions During Disassembly and Reassembly.......................................638 Check Points and Solutions for Problems..............................................639 Checking of Pilot Pressure for Defects...........................................639 Hydraulic Schematic (DX300LL-3) SP003075.....................................................641 Safety Instructions......................................................................645 Applicable Models........................................................................645 DX300LL-3................................................................................647 Electrical System................................................................................649 Electrical System SP003070...................................................................651 Safety Instructions......................................................................657 Applicable Models........................................................................657 Introduction.............................................................................658 Electrical Supply System.................................................................660 Engine Starting Circuit..................................................................662 Start Operation......................................................................662 After Start..........................................................................664 Engine Preheating System.................................................................666 Engine Stop..............................................................................668 Monitoring System........................................................................671 Instrument Panel.....................................................................672 Functional Check.....................................................................672 Monitoring System Schematic..........................................................674 Operation................................................................................676 Instruments..........................................................................676 Warning and Indicator Lights............................................................. 0 Indication of Multifunction Gauge....................................................680 Initial Operation........................................................................681 Graphic Information Area Display.........................................................682 Overview.............................................................................682 Main Menus for the Graphic Display Area..............................................682 Menu Selector Buttons................................................................682 Special Menu.............................................................................715 Entering/Accessing and Exiting/Escaping Menus........................................715 Special Menu Selections..............................................................716 Electronic Hydraulic Control System (EPOS)...............................................742 Control System Schematic.............................................................742 Power Plus Mode Control..................................................................744 Operation............................................................................746 Power Mode Control - Circuit Diagram.....................................................748 Engine Control System....................................................................750 Engine Control Dial......................................................................751 Engine Control Circuit Diagram...........................................................752 omatic Deceleration Control (Auto Idle Control)..........................................754 Engine Overheat Protection System........................................................756 Power Boost Mode.........................................................................758 Operation............................................................................758 Power Boost Control - Circuit Diagram................................................760 Automatic Travel Speed Control...........................................................762 Self-diagnostic Function.................................................................765 EPOS Controller......................................................................765 Air Conditioner System...................................................................767 Outline..............................................................................767 Internal and External Filters........................................................768 Air-Conditioning System Layout.......................................................770 Air Conditioner/heater Unit..........................................................772 Ambient Air Temperature Sensor.......................................................777 Compressor...........................................................................786 Receiver Dryer.......................................................................786 Troubleshooting..........................................................................787 Weight of R134a Gas Used In Machines.....................................................789 Refrigerant System Repairs...............................................................790 Refrigerant Safe Handling Procedures.................................................790 Repair and Replacement Procedure.....................................................791 Refrigerant Recovery.................................................................793 Vacuuming Refrigerant System.........................................................793 Leakage Check........................................................................795 Refrigerant Charging.................................................................795 Inspecting System For Leakage........................................................797 Wiper System............................................................................. 0 Wiper operation......................................................................799 Lighting System.......................................................................... 0 Kind of Light........................................................................803 Operation............................................................................803 Overload Warning Device..................................................................804 Overload Warning Device Circuit Diagram..............................................804 Electrical Schematic (DX300LL-3) SP003076....................................................807 Safety Instructions......................................................................811 Applicable Models........................................................................811 Attachments......................................................................................815 Boom and Stick SP003072......................................................................817 Safety Instructions......................................................................821 Applicable Models........................................................................821 Front Attachment Pin Specifications......................................................822 DX300LL..............................................................................823 Size and Weight Specifications.......................................................823 Front Attachment - Removal and Installation..............................................824 Stick Removal Procedure..............................................................824 Boom Removal Procedure...............................................................826 Installation.............................................................................827 Stick Installation Procedure.........................................................827 Boom Installation Procedure..........................................................827 Start-up Procedures......................................................................827
DOOSAN DX300LL-3 EXCAVATOR LOG LOADER SHOP MANUAL SN10001 & UP – PDF DOWNLOAD:
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