Doosan DX300LL Excavator Log Loader Operation & Maintenance Manual – PDF DOWNLOAD

Description

Doosan DX300LL Excavator Log Loader Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Doosan DX300LL Excavator Log Loader Operation & Maintenance Manual – PDF DOWNLOAD

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

Safety Features

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

TABLE OF CONTENTS:

Doosan DX300LL Excavator Log Loader Operation & Maintenance Manual – PDF DOWNLOAD

Safety..........................................................................................................  9
	To the Operator of a DOOSAN Daewoo Excavator................................................................  9
		Learn the Signal Words Used with the Safety Alert Symbol................................................ 10
	Location of Safety Labels................................................................................... 12
		1. Warnings for Operation, Inspection and Maintenance (19000688, 19000092)............................ 13
		2. Warnings for High Voltage (19000689, 19000096)..................................................... 13
		3. Warnings When Opening a Front Window (21903388, 19000093).......................................... 14
		4. Warnings for a Highpressure Cylinder (19000122).................................................... 14
		5. Warnings When Adjusting Track Tension (21903386A, 19000521)........................................ 15
		6. Warnings for Leaving Operator's Seat (19000693, 19000094).......................................... 15
		7. Warnings for Batteries Maintenance (21902533A, 19000100)........................................... 16
		8. Warnings for High Temperature Hydraulic Oil (19000691, 19000097)................................... 16
		9. Warnings for Hot Coolant (19000692, 19000097)...................................................... 17
		10. Warnings for Handling an Accumulator (19000703, 19000099)......................................... 17
		11. Warnings for Rotating Parts (19000694, 19000095, 19000557)....................................... 18
		12. Warning Tag  Used When Inspection and Maintenance (19000695, 19000098)........................... 18
		13. Warning for a Hot Surface (19000648A).............................................................. 19
		14. Caution for Hood (19000522)........................................................................ 19
		15. Keep Out of the Swing Area (21903379A, K1008571)................................................... 20
		16. Warnings for Front Attachments (19000652).......................................................... 20
		17. Warning for Intrusion Hazard (21903444)............................................................ 21
		18. Warning for Power Lines (21903450A)................................................................ 21
		19. Warning for Tilt Cabin (21903446).................................................................. 21
	Summary of Safety Precautions for Lifting in Digging Mode................................................... 22
	Unauthorized Modifications.................................................................................. 23
	General Hazard Information.................................................................................. 23
		Safety Rules............................................................................................ 23
		Safety Features......................................................................................... 23
		Inside Operator's Cabin................................................................................. 24
		Clothing and Personal Protective Items.................................................................. 25
		Breathing Masks, Ear Protection May Be Required......................................................... 25
		Vibration Level Information............................................................................. 25
		Recommendations for Limiting Vibrations................................................................. 25
		Mounting and Dismounting................................................................................ 26
		Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 27
		Precautions When Handling Fluids at High Temperature.................................................... 27
		Asbestos Dust Hazard Prevention......................................................................... 28
		Injury from Work Equipment.............................................................................. 28
		Fire Extinguisher and First Aid Kit..................................................................... 28
		Protection from Falling or Flying Objects............................................................... 29
		Attachment Precautions.................................................................................. 30
		Accumulator............................................................................................. 30
		Indoor Ventilation...................................................................................... 31
		Emergency Exit.......................................................................................... 31
	Before Starting Engine...................................................................................... 32
		Work Site Precautions................................................................................... 32
		Checks Before Starting Engine........................................................................... 33
		Engine Starting......................................................................................... 33
		Before Operating Machine................................................................................ 34
	Machine Operation........................................................................................... 36
		When Swinging or Changing Direction of Travel........................................................... 36
		Travel Precautions...................................................................................... 37
		Traveling on Slopes..................................................................................... 38
		Prohibited Operations................................................................................... 38
		Precautions for Operation............................................................................... 39
		Avoid Highvoltage Cables............................................................................... 40
		Operate Carefully on Snow, Ice and in Very Cold Temperatures............................................ 40
		Operations on Slopes.................................................................................... 41
		Parking Machine......................................................................................... 41
		Never Let Anyone Ride on Attachment..................................................................... 41
	Maintenance................................................................................................. 42
		Warning Tag............................................................................................. 42
		Clean Before Inspection or Maintenance.................................................................. 42
		Proper Tools............................................................................................ 43
		Use of Lighting......................................................................................... 43
		Fire Prevention and Explosion Prevention................................................................ 44
		Burn Prevention......................................................................................... 45
		Welding Repairs......................................................................................... 46
			Treatment for Electrical Welding to the Body Structure.............................................. 47
		Warning for Counterweight and Front Attachment Removal.................................................. 47
		Precautions for Removal, Installation, and Storage of Attachments....................................... 48
		Precautions When Working on Machine..................................................................... 48
		Lock Inspection Covers.................................................................................. 48
		Prevention of Crushing and Cutting...................................................................... 49
		Track Tension Adjustments Require Caution............................................................... 49
		Supports and Blocking for Work Equipment................................................................ 49
		Action When Abnormality Is Found During Inspection...................................................... 50
		Precautions with Highpressure Lines, Tubes and Hoses................................................... 50
		Waste Materials......................................................................................... 51
		Hydraulic Cylinders, Pins and Bushings.................................................................. 51
	Battery..................................................................................................... 52
		Battery Hazard Prevention............................................................................... 52
		Boost Starting or Charging Engine Batteries............................................................. 53
	Towing...................................................................................................... 54
		Precautions When Towing................................................................................. 54
	Shipping and Transportation................................................................................. 55
		Obey State and Local OvertheRoad Regulations.......................................................... 55
	Excavator Rated Lift Capacity Tables........................................................................ 56
Operating Controls.............................................................................................. 61
	Component Locations......................................................................................... 63
	Operator's Area............................................................................................. 65
	Operational Controls and Panels............................................................................. 67
		1. Starter Switch....................................................................................... 69
		2. Engine Speed Control Dial............................................................................ 69
		3. Auxiliary Mode Switch................................................................................ 70
		4. Engine Emergency Stop Switch......................................................................... 70
		5. Audio Control Panel.................................................................................. 70
		6. Travel Speed Selector Switch......................................................................... 72
		7. Light Switch......................................................................................... 72
		8. Cabin Work Light Switch.............................................................................. 72
		9. Blank (Empty Switch Socket).......................................................................... 73
		12. Heater and Air Conditioner Control Panel............................................................ 73
		13. Wiper Switch Panel.................................................................................. 73
			Constant Speed Button............................................................................... 73
			Intermittent Speed Button........................................................................... 74
			Windshield Washer Button............................................................................ 74
		14. Cigar Lighter....................................................................................... 74
		15. Power Socket for 12 Volt............................................................................ 75
		16. Travel/Swing Alarm Switch........................................................................... 75
		18. Fuel Heater Switch.................................................................................. 75
		19. Seat Warmer Switch (Optional)....................................................................... 76
		20. Horn Button (Left-hand Work Lever).................................................................. 76
		21. Rotating Buttons.................................................................................... 76
		22. Booster Button (Right-hand Work Lever).............................................................. 77
		23. Grapple Buttons..................................................................................... 77
		24. Instrument Panel.................................................................................... 77
		25. Safety Lever........................................................................................ 78
		26. Photo Sensor........................................................................................ 78
	Instrument Panel............................................................................................ 79
		Functional check........................................................................................ 80
		Password Activated...................................................................................... 80
		1. Fuel Gauge........................................................................................... 81
		2. Engine Coolant Temperature Gauge..................................................................... 81
		3. Hydraulic Oil Temperature Gauge...................................................................... 82
		4. Multifunction Gauge and Graphic Information Area..................................................... 82
		5. Digital Clock........................................................................................ 82
		6. Hour Meter........................................................................................... 83
		7. Charge Warning Light................................................................................. 83
		8. Engine Oil Pressure Warning Light.................................................................... 83
		9. Engine Coolant Temperature Warning Light............................................................. 84
		10. Engine Check Warning Light.......................................................................... 84
		11. Preheating Indicator Light.......................................................................... 85
		12. Work Light Indicator Light.......................................................................... 85
	Multifunction Gauge and Graphic Information................................................................. 86
		Communication Indicator................................................................................. 86
		Communication Error Warning............................................................................. 87
		Engine Speed............................................................................................ 87
		Battery Voltage......................................................................................... 87
		Front Hydraulic Pump Pressure........................................................................... 88
		Rear Hydraulic Pump Pressure............................................................................ 88
		Abnormal State Warning Symbols.......................................................................... 88
			Examples of Warning Display......................................................................... 89
			1. Hydraulic Oil Overheat Warning................................................................... 89
			2. Pilot Filter Clogged Warning..................................................................... 89
			3. Fuel Shortage Warning............................................................................ 90
			4. Return Filter Clogged Warning.................................................................... 90
			5. Air Cleaner Clogged Warning...................................................................... 90
	Mode Selector Buttons....................................................................................... 91
		1. Power Mode Selector Button........................................................................... 91
		2. Trenching Mode Selector Button....................................................................... 91
		3. Auto Idle Selector Button............................................................................ 92
		4. Flow Control Button.................................................................................. 92
	Setting Main Menu........................................................................................... 93
		1. Up Arrow Button...................................................................................... 93
		2. Down Arrow Button.................................................................................... 94
		3. Display Selector Button (ESC - Escape)............................................................... 94
		4. SelectionButton..................................................................................... 94
		Display Selection and Escaping.......................................................................... 95
			Display Selection................................................................................... 95
			ESC Button.......................................................................................... 95
		Main Menu............................................................................................... 95
		Language................................................................................................ 96
		Set Clock............................................................................................... 96
			Setting Method...................................................................................... 96
			'00' Minute Setting................................................................................. 97
		Filter / Oil Info....................................................................................... 97
			Menu Display Order and Icon Explanation............................................................. 98
			Filter / Oils Operating Hour Reset.................................................................. 98
		Adjust Display.......................................................................................... 99
		Set Password (Lock and Unlock)..........................................................................100
	Heater and Air Conditioner Control Panel....................................................................102
		Location of Controls and Vents..........................................................................102
		Control Panel...........................................................................................103
			1. Automatic Temperature Control Button.............................................................103
			2. Off Button.......................................................................................104
			3. Temperature Control Button.......................................................................104
			4. Temperature Unit Selector Button.................................................................104
			5. Mode Selector Button.............................................................................105
			6. Air Inlet Selector Button........................................................................106
			7. Fan Speed Selector Buttons.......................................................................106
			8. Air Conditioner Button...........................................................................107
			9. Defroster Button.................................................................................107
			10. LCD Display.....................................................................................107
		Memory Function.........................................................................................108
		Additional Operating Instructions.......................................................................108
	Stereo......................................................................................................109
		Stereo..................................................................................................109
		CD Player (Optional)....................................................................................109
	Miscellaneous Electrical Devices............................................................................110
		Cabin Light.............................................................................................110
		Pilot Cutoff Switch.....................................................................................110
		Circuit Breaker.........................................................................................110
		Fusible Link............................................................................................111
		Fuse Boxes..............................................................................................111
	Seat Adjustment.............................................................................................112
		1. Forward / Backward Adjustment........................................................................112
		2. Seat Tilt and Height Adjustment......................................................................112
			Forward Tilt........................................................................................112
			Rear Tilt...........................................................................................112
			Seat Height.........................................................................................112
		3. Suspension Adjustment................................................................................112
		4. Reclining Position Adjustment........................................................................113
		5. Armrest Angle Adjustment.............................................................................113
		6. Lumbar Support Adjustment............................................................................113
		7. Headrest.............................................................................................113
		8. Seat Belt............................................................................................114
			Seat Belt Locking and Unlocking.....................................................................114
		9. Seat Backpocket.....................................................................................115
		10. Left and Right Control Stand Adjustment.............................................................115
		11. Left and Right Control Stand Height Adjustment......................................................115
		12. Air Suspension Seat (Optional)......................................................................115
		13. Heating the Operator's Seat (Optional)..............................................................116
	Ceiling Cover...............................................................................................116
		Opening the Ceiling Cover...............................................................................116
		Closing the Ceiling Cover...............................................................................116
	Front Windows...............................................................................................117
		Front Upper Window......................................................................................117
			Opening the Window..................................................................................117
			Closing the Window..................................................................................118
		Front Bottom Window.....................................................................................118
	Doors and Access Covers.....................................................................................119
		Door Side Latch.........................................................................................119
		Cabin Riser Access Door.................................................................................119
	Tilt Cabin..................................................................................................120
	Cabin Storage Compartments..................................................................................120
	Ashtray.....................................................................................................121
	Sun Visor...................................................................................................121
	Hanger......................................................................................................122
	Cup Holder..................................................................................................122
	Door Window Holder..........................................................................................122
	Emergency Glass Breaking Tool...............................................................................123
	Miscellaneous Access Covers and Doors.......................................................................124
		Side Door...............................................................................................124
		Battery Box Door........................................................................................124
			Opening.............................................................................................124
			Closing.............................................................................................124
		Engine Cover............................................................................................124
Operation.......................................................................................................125
	To Handle a New Excavator...................................................................................125
		Lubrication and Filters.................................................................................126
	Starting and Stopping the Engine............................................................................126
		Inspection Before Starting Engine.......................................................................126
		Operational Checks Before Starting Engine...............................................................127
		Engine Start............................................................................................128
		Cold Weather Starting...................................................................................130
		Starting Engine With a Booster Cable....................................................................131
			Connecting the Booster Batteries....................................................................132
			Disconnecting the Booster Batteries.................................................................132
		Hydraulic System Warmup................................................................................133
		Hydraulic System Warmup – Cold Weather.................................................................134
		Engine Shut Down........................................................................................135
		Check and Confirmation After Stopping Engine............................................................136
	Safety Lever................................................................................................137
	Travel......................................................................................................138
		Automatic Travel Speed Control..........................................................................138
		Travel Control Lever Operation..........................................................................140
		General Travel Instructions.............................................................................141
	Operating Instructions......................................................................................144
		Engine Speed Control....................................................................................144
		Mode Selection..........................................................................................144
			Power Mode..........................................................................................144
			Work Mode...........................................................................................145
			Auto Idle Mode......................................................................................145
			Boost Mode..........................................................................................146
		Work Levers (Joysticks) (ISO Style).....................................................................146
			Lefthand Work Lever (Joystick) (Figure 44 and Figure 45)...........................................146
			Righthand Work Lever (Joystick) (Figure 44 and Figure 47)..........................................147
	Operating Precautions.......................................................................................148
		Always Observe These Precautions........................................................................150
		Working in Water........................................................................................151
	Parking Excavator...........................................................................................152
	Towing Procedure............................................................................................153
	Operating Techniques........................................................................................154
		Lifting.................................................................................................154
			Lifting Unknown Weight..............................................................................154
			Lifting Known Weight................................................................................155
			Pick and Carry......................................................................................155
	Operation Under Unusual Conditions..........................................................................156
		Operation In Extreme Cold...............................................................................156
		Operation in Extreme Heat...............................................................................157
		Operation in Dusty or Sandy Areas.......................................................................158
		Operation in Rainy or Humid Conditions..................................................................158
		Operation in Salt Water Areas...........................................................................159
		Operation at High Altitudes.............................................................................159
Inspection, Maintenance and Adjustment..........................................................................161
	Preventive Maintenance......................................................................................161
		Product Identification Number (P. I. N.) Location.......................................................162
		Component Serial Numbers................................................................................162
		Safety Precautions......................................................................................163
	Preliminary Work Machine Setup for Maintenance..............................................................164
	Table of Recommended Lubricants.............................................................................166
	Fluid Capacities............................................................................................168
	Lubrication and Service Chart...............................................................................168
		Description of Lubrication and Service Chart............................................................170
	Maintenance Intervals.......................................................................................172
	10 Hour / Daily Service.....................................................................................174
		Grease Hoist, Stick and Front Attachment Pins (for first 100 hours).....................................174
		Check Engine Oil Level..................................................................................174
		Check Level of Hydraulic Oil Tank.......................................................................175
		Check for Leaks in Hydraulic System.....................................................................176
		Check Fuel Level........................................................................................177
		Check for Leaks in Fuel System..........................................................................177
		Check Fuel Prefilter and Drain Water As Required........................................................178
		Check Oil Level of Swing Reduction Device...............................................................178
		Clean Dust Net in Front of Oil Cooler and Intercooler...................................................180
		Check Cooling System and Refill As Required.............................................................180
		Check Level of Window Washer Liquid.....................................................................181
		Inspect Cooling Fan Blade...............................................................................181
		Check Air Intake System.................................................................................182
		Inspect Seat Belt for Proper Operation..................................................................182
		Inspect the Structure for Cracks and Faulty Welds.......................................................182
		Check the Operation of All Switches.....................................................................182
		Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......183
		Start Engine, Check Starting Ability, and Observe Exhaust Color at Startup and at Normal Operati.......183
		Check Operation of All Controls.........................................................................183
	50 Hour / Weekly Service....................................................................................184
		Perform All Daily Service Checks........................................................................184
		Grease Hoist and Front Attachment Pins..................................................................184
		Grease Swing Bearing....................................................................................189
		Drain Water and Sediment from Fuel Tank.................................................................190
		Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours).......................190
		Change Engine Oil and Filter (After First 50 Hours).....................................................190
		Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, R.......190
	250 Hour / Monthly Service..................................................................................191
		Perform All Daily and 50 Hour Service Checks............................................................191
		Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours)..............................191
		Check Engine Fan Belt Tension...........................................................................191
		Check Engine Fan Belt Wear..............................................................................192
		Check Oil Level in Travel Reduction Device (One on Each Side of Unit)...................................193
		Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 250 Hours)................193
		Replace Hydraulic Oil Return Filter (After First 250 Hours).............................................193
		Change Pilot Filter (After First 250 Hours).............................................................193
		Inspect Pins and Bushings of the Front End Attachments for Signs of Wear................................194
		Check Fluid Levels in Batteries and Battery Charge Levels...............................................194
		Inspect for Any Loose or Missing Nuts and Bolts.........................................................194
		Inspect Fuel System Hose Clamps.........................................................................194
	500 Hour / 3 Month Service..................................................................................195
		Perform All Daily, 50 and 250 Hour Service Checks.......................................................195
		Grease Swing Gear and Pinion............................................................................195
		Change Engine Oil and Filter............................................................................195
		Clean AirConditioning Outer Filter.....................................................................196
		Check and Clean AirConditioning Inner Filter...........................................................198
		Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core.................199
		Clean Outer Filter of Air Cleaner.......................................................................200
		Change of Fuel Prefilter................................................................................201
		Change Fuel Filter......................................................................................202
			Fuel System Priming.................................................................................203
	1,000 Hour / 6 Month Service................................................................................204
		Perform All Daily, 50, 250 and 500 Hour Service Checks..................................................204
		Grease Swing Reduction Device...........................................................................204
		Change Pilot Filter.....................................................................................206
		Change Oil in Travel Reduction Device (One on Each Side of Unit)........................................207
		Change AirConditioning Outer Filter....................................................................207
		Check Air Conditioner Refrigerant.......................................................................208
		Check and Adjust Engine **..............................................................................210
	2,000 Hour / Yearly Service.................................................................................211
		Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks...........................................211
		Change Swing Reduction Device Oil.......................................................................211
		Replace Outer and Inner Air Cleaner Elements............................................................212
		Change Radiator Coolant.................................................................................213
		Hydraulic Oil Exchange and Suction Strainer Cleaning....................................................214
		Check Alternator and Starter**..........................................................................216
		Check All Rubber Antivibration Shock Mounts.............................................................216
		Perform and Record the Results of the Cycle Time Tests..................................................216
		Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.........................216
		Check, Adjust Valve Clearance **........................................................................216
		Check Head Bolt Torques.................................................................................216
	4,000 Hour / Biennial Service...............................................................................217
		Major Parts  Periodic Replacement......................................................................217
	12,000 Hour / Six Year Service..............................................................................218
		Hose Inservice Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................218
	AirConditioning System.....................................................................................219
		Check Control Panel.....................................................................................219
		Check Air Conditioner Hoses.............................................................................219
		Check Condenser.........................................................................................219
		Check Magnetic Clutch...................................................................................219
		Check Belt Tension......................................................................................219
	Bolt and Nut Inspection.....................................................................................220
	Electrical System...........................................................................................228
		Battery.................................................................................................228
			Batteries in Cold Weather...........................................................................228
			Inspection of Battery Electrolyte Level.............................................................229
			Check Charging State................................................................................229
			Check the Battery Terminals.........................................................................229
			Battery Replacement.................................................................................229
		Fuses...................................................................................................229
			Fuse Boxes..........................................................................................230
			Fuse Identification.................................................................................231
	Engine Cooling System.......................................................................................232
		General.................................................................................................232
		Measuring the Concentration of Coolant..................................................................233
			Types of Antifreeze.................................................................................235
		Antifreeze Concentration Tables.........................................................................235
	Fuel Transfer Pump (Option).................................................................................236
	Handling of Accumulator.....................................................................................239
	Track Tension...............................................................................................240
	Venting and Priming Hydraulic System........................................................................242
		Main System Pump........................................................................................242
		Hydraulic Cylinders.....................................................................................242
		Swing Motor.............................................................................................243
		Travel Motor............................................................................................243
		General Venting.........................................................................................243
	Long Term Storage...........................................................................................244
	Maintenance in Special Conditions...........................................................................245
Transportation..................................................................................................247
	Loading and Unloading.......................................................................................247
		Warning for Counterweight and Front Attachment Removal..................................................247
	Lifting With Sling..........................................................................................251
Troubleshooting.................................................................................................253
	Electrical System...........................................................................................253
	Engine......................................................................................................254
	Hydraulic System............................................................................................256
	Swing System................................................................................................257
	Travel System...............................................................................................257
Specification...................................................................................................259
	Standard Specification......................................................................................259
	Overall Dimensions..........................................................................................260
	Working Range...............................................................................................262
	Approximate Weight of Workload Materials....................................................................263
Index...........................................................................................................265
Publication Request for Proposed Revision.......................................................................269

DOOSAN DX300LL EXCAVATOR LOG LOADER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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