Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Doosan DX300LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Original price was: $65.95.$31.95Current price is: $31.95.
Doosan DX300LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Serial Number 5001 thru 5061
K1011789E-1
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Doosan DX300LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
DESCRIPTION:
Doosan DX300LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Serial Number 5001 thru 5061
K1011789E-1
GENERAL SAFETY ESSENTIALS
Accessory Applications
- The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN for proper installation and application.
- Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading. DO NOT use the machine for activities for which it was not intended.
- DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration. Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.
Lifting Capacity Rating Configuration
- Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration. Loads must be balanced and supported evenly.
- Use tag lines to keep the load steady if wind conditions and large surface area are a problem. Work crew hand signals, individual tasks and safe procedures should all be universally understood before the lift is made.
TABLE OF CONTENTS:
Doosan DX300LL Excavator Log Loader Shop Manual – PDF DOWNLOAD
Table of Contents....................................................................................................... 7 Publication Request for Proposed Revision............................................................................... 9 Safety.................................................................................................................. 11 Track Excavator Safety.............................................................................................. 13 Safety Precautions.............................................................................................. 17 Applicable Models............................................................................................... 17 To the Operator of a DOOSAN Daewoo Excavator.................................................................... 18 Learn the Signal Words Used with the Safety Alert Symbol.................................................... 20 General Safety Essentials....................................................................................... 22 Accessory Applications...................................................................................... 22 Lifting Capacity Rating Configuration....................................................................... 22 Location of Safety Labels....................................................................................... 23 Summary of Safety Precautions for Lifting in Digging Mode....................................................... 24 Unauthorized Modifications...................................................................................... 25 General Hazard Information...................................................................................... 25 Safety Rules................................................................................................ 25 Safety Features............................................................................................. 25 Inside Operator's Cabin..................................................................................... 26 Clothing and Personal Protective Items...................................................................... 26 Breathing Masks, Ear Protection May Be Required............................................................. 27 Vibration Level Information................................................................................. 27 Recommendations for Limiting Vibrations..................................................................... 27 Mounting and Dismounting.................................................................................... 28 Fuel, Oil and Hydraulic Fluid Fire Hazards.................................................................. 29 Precautions When Handling Fluids at High Temperature........................................................ 29 Asbestos Dust Hazard Prevention............................................................................. 30 Injury from Work Equipment.................................................................................. 30 Fire Extinguisher and First Aid Kit......................................................................... 30 Protection from Falling or Flying Objects................................................................... 31 Attachment Precautions...................................................................................... 32 Accumulator................................................................................................. 32 Indoor Ventilation.......................................................................................... 33 Emergency Exit.............................................................................................. 33 Before Starting Engine.......................................................................................... 34 Work Site Precautions....................................................................................... 34 Checks Before Starting Engine............................................................................... 35 Engine Starting............................................................................................. 36 Before Operating Machine.................................................................................... 36 Machine Operation............................................................................................... 38 When Swinging or Changing Direction of Travel............................................................... 38 Travel Precautions.......................................................................................... 39 Traveling on Slopes......................................................................................... 40 Prohibited Operations....................................................................................... 40 Precautions for Operation................................................................................... 41 Avoid Highvoltage Cables................................................................................... 42 Operate Carefully on Snow, Ice and in Very Cold Temperatures................................................ 42 Operations on Slopes........................................................................................ 43 Parking Machine............................................................................................. 43 Never Let Anyone Ride on Attachment......................................................................... 43 Maintenance..................................................................................................... 44 Warning Tag................................................................................................. 44 Clean Before Inspection or Maintenance...................................................................... 44 Proper Tools................................................................................................ 45 Use of Lighting............................................................................................. 45 Fire Prevention and Explosion Prevention.................................................................... 45 Burn Prevention............................................................................................. 46 Welding Repairs............................................................................................. 46 Treatment for Electrical Welding to the Body Structure.................................................. 47 Warning for Counterweight and Front Attachment Removal...................................................... 48 Precautions for Removal, Installation, and Storage of Attachments........................................... 48 Precautions When Working on Machine......................................................................... 49 Lock Inspection Covers...................................................................................... 49 Prevention of Crushing and Cutting.......................................................................... 50 Track Tension Adjustments Require Caution................................................................... 50 Supports and Blocking for Work Equipment.................................................................... 50 Action When Abnormality Is Found During Inspection.......................................................... 51 Precautions with Highpressure Lines, Tubes and Hoses....................................................... 51 Waste Materials............................................................................................. 52 Hydraulic Cylinders, Pins and Bushings...................................................................... 52 Battery......................................................................................................... 53 Battery Hazard Prevention................................................................................... 53 Boost Starting or Charging Engine Batteries................................................................. 54 Towing.......................................................................................................... 55 Precautions When Towing..................................................................................... 55 Shipping and Transportation..................................................................................... 56 Obey State and Local OvertheRoad Regulations.............................................................. 56 Lifting With Sling.............................................................................................. 56 Specifications.......................................................................................................... 57 Specification for DX300LL........................................................................................... 59 Safety Precautions.............................................................................................. 63 Applicable Models............................................................................................... 63 General Description............................................................................................. 65 Component Locations............................................................................................. 66 General Dimensions.............................................................................................. 68 Working Range................................................................................................... 70 General Specifications.......................................................................................... 71 Engine Performance Curves (Per DIN6270 Standard)............................................................... 72 Approximate Weight of Workload Materials........................................................................ 74 Performance Tests............................................................................................... 76 Log Loader Performance Standards................................................................................ 77 Test Conditions............................................................................................. 77 Travel Speed and Travel Motor Balance (Steering Deviation) Tests............................................ 77 Speed Test.............................................................................................. 77 Travel Deviation........................................................................................ 79 Swing Speed and Deceleration Force Test..................................................................... 79 Swing Speed Test........................................................................................ 79 Swing Deceleration Force Test........................................................................... 80 Cylinder Performance Tests.................................................................................. 81 Hoist Cylinders Test.................................................................................... 81 Stick Cylinder Test..................................................................................... 81 Heel Cylinder Test...................................................................................... 81 Hydraulic Cylinder Natural Drop Test.................................................................... 81 Travel Motor Jackup Test............................................................................... 82 General Maintenance..................................................................................................... 83 General Maintenance Procedures...................................................................................... 85 Safety Precautions.............................................................................................. 89 Applicable Models............................................................................................... 89 Welding Precautions and Guidelines.............................................................................. 90 Hydraulic System General Precautions.......................................................................... 91 Maintenance Service and Repair Procedure........................................................................ 93 General Precautions......................................................................................... 93 Hydraulic System Cleanliness and Oil Leaks...................................................................... 94 Maintenance Precautions for Hydraulic System Service........................................................ 94 Oil Leakage Precautions..................................................................................... 95 Cleaning and Inspection......................................................................................... 96 General Guidelines.......................................................................................... 96 Bearing inspection.......................................................................................... 97 Normal Bearing.......................................................................................... 98 Bent Cage............................................................................................... 98 Galling................................................................................................. 99 Abrasive Step Wear...................................................................................... 99 Etching.................................................................................................100 Misalignment............................................................................................100 Indentations............................................................................................100 Fatigue Spalling........................................................................................101 Brinelling..............................................................................................101 Cage Wear...............................................................................................101 Abrasive Roller Wear....................................................................................102 Cracked Inner Race......................................................................................102 Smears..................................................................................................102 Frettage................................................................................................103 Heat Discoloration......................................................................................103 Stain Discoloration.....................................................................................103 Standard Torques....................................................................................................105 Safety Precautions..............................................................................................109 Applicable Models...............................................................................................109 Torque Values for Standard Metric Fasteners.....................................................................110 Torque Values for Standard U.S. Fasteners.......................................................................111 Type 8 Phosphate Coated Hardware................................................................................113 Torque Values for Hose Clamps...................................................................................114 Torque Values for Split Flanges.................................................................................115 Torque Wrench Extension Tools...................................................................................116 Torque Multiplication.......................................................................................116 Other Uses for Torque Wrench Extension Tools................................................................117 Tightening Torque Specifications (Metric)...................................................................117 I. "Loctite" Fastener Adhesives.........................................................................119 II. "Loctite" Pipe Thread Sealant.......................................................................119 III. "Loctite" gasket/flange sealer.....................................................................119 IV. "Loctite" retaining compounds.......................................................................120 V. "Loctite" Adhesives..................................................................................120 Upper Structure.........................................................................................................121 Cabin...............................................................................................................123 Safety Precautions..............................................................................................127 Applicable Models...............................................................................................127 Removal.........................................................................................................128 Installation....................................................................................................132 Counterweight.......................................................................................................135 Safety Precautions..............................................................................................139 Applicable Models...............................................................................................139 General.........................................................................................................140 Warning for Counterweight and Front Attachment Removal......................................................140 Removal.........................................................................................................142 Installation....................................................................................................144 Fuel Tank...........................................................................................................145 Safety Precautions..............................................................................................149 Applicable Models...............................................................................................149 General Description.............................................................................................150 Parts List..................................................................................................150 Specifications..............................................................................................151 Removal.........................................................................................................152 Installation....................................................................................................157 Startup Procedures.............................................................................................160 Fuel Transfer Pump..................................................................................................161 Safety Precautions..............................................................................................165 Applicable Models...............................................................................................165 General Description.............................................................................................166 Theory of Operation.........................................................................................166 Troubleshooting.................................................................................................167 Replacement of Rotor and Vane...................................................................................167 Replacement of Rear Cover.......................................................................................168 Replacement of Armature.........................................................................................168 Swing Bearing.......................................................................................................169 Safety Precautions..............................................................................................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 Rebuilding Swing Bearing....................................................................................175 Swing Reduction Gear................................................................................................177 Safety Precautions..............................................................................................181 Applicable Models...............................................................................................181 General Description.............................................................................................183 Theory of Operation.........................................................................................183 Parts List..................................................................................................184 Specifications..............................................................................................185 Troubleshooting, Testing and Adjustment.........................................................................186 Removal.........................................................................................................187 Disassembly.....................................................................................................188 Cleaning and Inspection (Wear Limits and Tolerances)............................................................197 Reassembly......................................................................................................198 Shaft and S/R Bearing Heatfit..............................................................................198 Assembly of Carrier Subassemblies...........................................................................198 Cleaning Carrier........................................................................................198 Cleaning Planet Gear....................................................................................198 Assembly of No. 1 Carrier...............................................................................198 Assembly of No. 2 Carrier...............................................................................201 Assembly of Main Case.......................................................................................204 Cleaning Casing and Other Parts.........................................................................204 Assembly of Shaft and Pinion............................................................................204 Assembly of Seal and Bearing............................................................................209 Assembly of Ring Gear...................................................................................213 Assembly of Carrier.....................................................................................215 Assembly of Motor...........................................................................................220 Add Gear Oil............................................................................................220 Assembly of Motor.......................................................................................220 Supply of Grease........................................................................................222 Installation....................................................................................................224 Startup Procedures.............................................................................................225 Lower Structure and Chassis.............................................................................................227 Track Assembly......................................................................................................229 Safety Precautions..............................................................................................233 Applicable Models...............................................................................................233 General Description.............................................................................................234 Track Tension...................................................................................................234 Cleaning and Inspection (Wear Limits and Tolerances)............................................................237 Track Shoe..................................................................................................238 Lower Roller................................................................................................240 Upper Roller................................................................................................241 Front Idler.................................................................................................242 Track Shoes and Links...........................................................................................243 Track Removal...............................................................................................243 Track Installation..........................................................................................244 Front Idler Roller..............................................................................................246 Parts List..................................................................................................246 Front Idler Roller Disassembly..............................................................................247 Front Idler Roller Reassembly...............................................................................248 Lower and Upper Roller..........................................................................................250 Parts List..................................................................................................250 Lower and Upper Roller Removal..............................................................................251 Lower and Upper Roller Disassembly..........................................................................251 Lower and Upper Roller Reassembly...........................................................................252 Lower and Upper Roller Installation.........................................................................253 Track Spring and Track Adjusting Cylinder.......................................................................254 Parts List..................................................................................................254 Engine and Drivetrain...................................................................................................257 Drive Coupling (Main Pump)..........................................................................................259 Safety Precautions..............................................................................................263 Applicable Models...............................................................................................263 Drive Coupling..................................................................................................264 Installation of Drive Coupling..................................................................................265 Installation Procedure......................................................................................265 Hydraulic System Troubleshooting, Testing and Adjustment............................................................267 Safety Precautions..............................................................................................271 Applicable Models...............................................................................................271 Hydraulic System General Notes................................................................................272 Hydraulic Schematic.............................................................................................273 General Notes...............................................................................................273 Operation of Working Components.................................................................................275 Boom Operating Circuit......................................................................................275 Boom Up Circuit.............................................................................................275 Boom Down Circuit...........................................................................................275 Arm Operating Circuit.......................................................................................276 Arm Crowd Circuit...........................................................................................276 Arm Dump Circuit............................................................................................276 Bucket Operating Circuit....................................................................................277 Bucket Crowd Circuit........................................................................................277 Bucket Dump Circuit.........................................................................................277 Swing Operating Circuit.....................................................................................277 Right Swing Operating Circuit...............................................................................278 Left Swing Operating Circuit................................................................................278 Swing Relief Valve and Makeup Valve.........................................................................278 Travel Operating Circuit....................................................................................278 Forward Travel Circuit......................................................................................279 Reverse Travel Circuit......................................................................................279 Procedural Troubleshooting Baseline Recommendations.............................................................280 Initial Checks and Tests to Establish Operating Condition of the Excavator..................................280 Triage Summary..........................................................................................280 Pilot Pressure..................................................................................................282 Adjustment and Testing......................................................................................282 Power Mode Valve................................................................................................283 Current Signal and Hydraulic Pressure Adjustments...........................................................283 Swing Priority Valve............................................................................................284 Control Valve Pressure and Current Adjustments..............................................................284 Pressure Up Valve...............................................................................................286 Checks and Adjustments......................................................................................286 Pump Input Power Control........................................................................................288 Pump Regulator Adjustment...................................................................................288 Flow Meter and Flow Meter Kit Installation and Testing..........................................................292 Installation and Testing Procedure..........................................................................292 Swing System Troubleshooting....................................................................................294 Precautions/Initial Checks..................................................................................294 Swing Relief Valve Checking and Adjustment..................................................................295 Troubleshooting – Swing Gearbox.................................................................................297 Troubleshooting – Hydraulic Problems............................................................................298 Troubleshooting – Control Valve.................................................................................300 Troubleshooting – Travel Control Valve..........................................................................301 Troubleshooting – Joystick Control Valve........................................................................302 Hydraulics..............................................................................................................303 Accumulator.........................................................................................................305 Safety Precautions..............................................................................................309 Applicable Models...............................................................................................309 General Description.............................................................................................310 Specifications..............................................................................................312 Center Joint (Swivel)...............................................................................................313 Safety Precautions..............................................................................................317 Applicable Models...............................................................................................317 General Description.............................................................................................318 Parts List..................................................................................................319 Troubleshooting, Testing and Adjustment.........................................................................320 Inspection..................................................................................................320 Testing.....................................................................................................320 Disassembly.....................................................................................................321 Reassembly......................................................................................................322 Cylinders...........................................................................................................323 Safety Precautions..............................................................................................327 Applicable Models...............................................................................................327 General Description.............................................................................................328 Theory of Operation.........................................................................................328 Parts List..................................................................................................330 Special Tools and Materials.....................................................................................332 Piston Nut..................................................................................................332 Piston Jig..................................................................................................334 Steel Bushing Jig...........................................................................................336 Dust Wiper Jig..............................................................................................338 Slipper Seal Jig............................................................................................340 Slipper Seal Straightening Jig..............................................................................342 Disassembly.....................................................................................................344 Reassembly......................................................................................................349 Swing Motor.........................................................................................................353 Safety Precautions..............................................................................................357 Applicable Models...............................................................................................357 General Description.............................................................................................358 Theory of Operation.........................................................................................358 Structure...............................................................................................358 Circuit Diagram.........................................................................................358 Generation of Rotary Power..............................................................................359 Operation of Relief Valve...............................................................................360 Operation of Parking Brake..............................................................................360 Makeup Check Valve..........................................................................................361 Operation of Time Delay Valve...............................................................................361 External Pilot Pressure: When Pi = 0 (Large Tilt Angle).................................................361 Operation of Swing Reactionless Valve.......................................................................361 Parts List..................................................................................................362 Specifications..............................................................................................363 Torques.....................................................................................................363 Tools and Materials.............................................................................................364 Tools.......................................................................................................364 Troubleshooting, Testing and Adjustment.........................................................................365 General Precautions.........................................................................................365 How to Check Faults of Hydraulic Motor......................................................................365 Troubleshooting.............................................................................................365 Disassembly.....................................................................................................367 General Cautions............................................................................................367 Disassembly.................................................................................................367 Cleaning and Inspection (Wear Limits and Tolerances)............................................................375 Reassembly......................................................................................................376 General Cautions............................................................................................376 Assembly....................................................................................................376 Assembly of Cylinder Block Assembly Subassembly.............................................................379 Assembly of Rear Cover Assembly Subassembly.................................................................383 Air Pressure Test...........................................................................................389 Oil Leakage Check...........................................................................................389 Travel Motor........................................................................................................391 Safety Precautions..............................................................................................395 Applicable Models...............................................................................................395 General Description.............................................................................................396 Theory of Operation.........................................................................................397 Hydraulic Motor.........................................................................................397 Operation of Reduction Gear.............................................................................404 Parts List..................................................................................................405 Hydraulic Motor.........................................................................................405 Reduction Gear..........................................................................................408 Specifications..............................................................................................409 Special Tools and Materials.....................................................................................410 Hydraulic Motor Part........................................................................................410 Reduction Gear Part.........................................................................................411 Tightening Torque Chart.....................................................................................412 Troubleshooting, Testing and Adjustment.........................................................................413 General Precautions.........................................................................................413 Troubleshooting.............................................................................................413 Disassembly.....................................................................................................417 General Caution Matters.....................................................................................417 Reduction Gear Part.........................................................................................417 Hydraulic Motor Part........................................................................................423 Disassembly of Main Body of Motor Section...............................................................423 Disassembly of Valve Casing Subassembly.................................................................426 Disassembly of Cylinder Block Assembly..................................................................427 Cleaning and Inspection (Wear Limits and Tolerances)............................................................428 Maintenance Standard........................................................................................428 Changing Standard of Hydraulic Motor Part...............................................................428 Parts Inspection and Inspection Standard of Reduction Gear..............................................430 Reassembly......................................................................................................431 General Caution Matters.....................................................................................431 Hydraulic Motor Part........................................................................................431 Reassembling of Driveshaft Subassembly..................................................................431 Assembly of Valve Casing Subassembly....................................................................431 Assembly of Valve Casing Subassembly....................................................................432 Assembly of Cylinder Subassembly........................................................................434 Reduction Gear Part.....................................................................................439 Checkup after Assembly......................................................................................447 Air Test for Reduction Gear.............................................................................447 Air Test for Motor......................................................................................447 Performance Test............................................................................................447 If Test Equipment Is Available..........................................................................447 If onsite performance test is unavoidable as test equipment is not available...........................448 Installation....................................................................................................449 Check.......................................................................................................449 Piping......................................................................................................449 Gear Oil....................................................................................................449 Kind of Oil.............................................................................................449 Oil Drain...............................................................................................450 Oil Filling.................................................................................................450 General Caution Matters.....................................................................................450 Main Control Valve..................................................................................................451 Safety Precautions..............................................................................................455 Applicable Models...............................................................................................455 General Description.............................................................................................457 Theory of Operation.........................................................................................457 When All Spools are in Neutral..........................................................................457 Single Operation........................................................................................462 Compound Operation......................................................................................476 Antidrift Valve.........................................................................................482 Main Relief Valve.......................................................................................483 Overload Relief Valve...................................................................................484 Lowpressure Relief Valve...............................................................................485 Parts List..................................................................................................486 Specifications..............................................................................................491 Troubleshooting, Testing and Adjustment.........................................................................492 Troubleshooting.............................................................................................492 Overall Control Valve...................................................................................492 Relief Valve............................................................................................493 Overall Oil Pressure....................................................................................493 Adjustment of Valves........................................................................................493 Main Relief Valve.......................................................................................493 Overload Relief Valve...................................................................................494 Disassembly.....................................................................................................495 Caution in Disassembly......................................................................................495 Disassembly of Main Spool Part..............................................................................496 Disassembly of Arm 1 Paraturn Spool Part...................................................................497 Disassembly of Arm Regeneration Release Valve Part..........................................................497 Disassembly of Load Check Valve Part........................................................................498 Disassembly of Antidrift Valve Part.........................................................................499 Disassembly of Relief Valve.................................................................................500 Disassembly of Option Section Part..........................................................................500 Disassembly of Other Plugs..................................................................................500 Disassembly of Valve Housing Bolt...........................................................................501 Disassembly of Main Relief Valve............................................................................502 Disassembly of Overload Relief Valve........................................................................503 Instruction of Disassembly and Assembly of Lowpressure Relief Valve........................................504 Cleaning and Inspection (Wear Limits and Tolerances)............................................................505 Cleaning....................................................................................................505 Inspection..................................................................................................505 Reassembly......................................................................................................506 Caution on Assembly.........................................................................................506 Caution on Handling Oring..............................................................................506 Caution on Handling Spool...............................................................................506 Method of Painting the Adhesives (screw part and arm screw part of parts requiring the adhesiveness)....506 Sequence of Subassembly.....................................................................................507 Spool Assembly (Main Spool).............................................................................507 Arm 1 Paraturn Spool Assembly..........................................................................507 Antidrift Valve Assembly................................................................................508 Assembly Sequence of Main Body of the Control Valve.....................................................508 Assembly of Relief Valve................................................................................509 Assembly of Load Check Valve............................................................................509 Assembly of Antidrift Valve.............................................................................510 Assembly of Option Section Part.........................................................................510 Assembly of Arm Regeneration Release Valve..............................................................510 Assembly of Arm 1 Paraturn Spool.......................................................................511 Assembly of Main Spool..................................................................................511 Assembly of Other Plugs.................................................................................512 Maintenance of Relief Valves................................................................................513 Reassembly of Main Relief Valve.........................................................................513 Reassembly of Overload Relief Valve (69, Total of 6 Places).............................................514 Reassembly of Lowpressure Relief Valve (70, Total of 2 Places).........................................515 Installation....................................................................................................516 Startup Procedures.............................................................................................516 Axial Piston Pump...................................................................................................517 Safety Precautions..............................................................................................521 Applicable Models...............................................................................................521 Axial Piston Pump...............................................................................................522 General Description.........................................................................................522 Model Number Designation................................................................................522 Theory of Operation.....................................................................................523 Parts List..............................................................................................524 Torques.................................................................................................526 Special Tools and Materials.................................................................................527 Tools...................................................................................................527 Troubleshooting, Testing and Adjustment.....................................................................529 Disassembly.................................................................................................531 Cleaning and Inspection (Wear Limits and Tolerances)........................................................534 Worn Part Replacement Criteria..........................................................................534 Correction Criteria for Cylinder, Valve Plate and Swash Plate (Shoe Plate)..............................535 Reassembly..................................................................................................536 Startup Procedures.........................................................................................540 Oil filling and Air Venting.............................................................................540 Cautions During Starting Operation......................................................................540 Regulator for Axial Piston Pump.................................................................................541 General Description.........................................................................................541 Model Number Designation................................................................................541 Parts List..............................................................................................542 Outline.................................................................................................543 Specifications..........................................................................................545 Functional Explanations.................................................................................545 Tightening Torque.......................................................................................551 Special Tools and Materials.................................................................................552 Tools...................................................................................................552 Troubleshooting, Testing and Adjustment.....................................................................552 Prime Mover is Overloaded...............................................................................552 Maximum Flow Is Not Available...........................................................................553 Adjustment of Maximum and Minimum Flows.................................................................553 Preparation for Disassembly.................................................................................555 Regulator Disassembly.......................................................................................555 Regulator Reassembly........................................................................................558 Remote Control Valve (Work Lever / Joystick)........................................................................561 Safety Precautions..............................................................................................565 Applicable Models...............................................................................................565 General Description.............................................................................................567 Theory of Operation.........................................................................................567 Structure...............................................................................................567 Function................................................................................................567 Parts List..................................................................................................568 Specifications..............................................................................................570 Performance.............................................................................................570 Torques.....................................................................................................570 Tools and Materials.............................................................................................570 Disassembly.....................................................................................................571 Cleaning and Inspection (Wear Limits and Tolerances)............................................................575 Reassembly......................................................................................................575 Startup Procedures.............................................................................................581 Travel Control Valve (with Damper)..................................................................................583 Safety Precautions..............................................................................................587 Applicable Models...............................................................................................587 General Description.............................................................................................589 Theory of Operation.........................................................................................589 Deceleration Valve..........................................................................................590 Dampening Parts of the Control Section......................................................................591 Causes of Faults and Measures...................................................................................593 Parts List..................................................................................................594 Specifications..............................................................................................595 Torques.....................................................................................................595 Removal.........................................................................................................596 Disassembly.....................................................................................................597 Cleaning and Inspection (Wear Limits and Tolerances)............................................................600 Assembly........................................................................................................601 Installation....................................................................................................607 Startup Procedures.............................................................................................608 Solenoid Valve Assembly.............................................................................................609 Safety Precautions..............................................................................................613 Applicable Models...............................................................................................613 Parts List......................................................................................................614 Functions of 5Solenoid Valve Assembly Package..................................................................615 Functions of Solenoid Valve Assembly Package................................................................615 This solenoid valve assembly package have the following functions.......................................615 Functions and Operations of Solenoid Valves.............................................................615 Detailed Functions and Operations of Solenoid Valves....................................................615 Assembly Diagram and Tools Required.........................................................................617 Cautions During Disassembly and Reassembly..............................................................618 Solenoid Valve Diagram......................................................................................619 Check Points and Solutions for Problems.....................................................................620 Checking of Pilot Pressure for Defects..................................................................621 Hydraulic Schematic (DX300LL).......................................................................................623 Safety Precautions..............................................................................................627 Applicable Models...............................................................................................627 General Description.............................................................................................629 DX300LL.........................................................................................................630 Electrical System.......................................................................................................633 Air Conditioner.....................................................................................................635 Safety Precautions..............................................................................................639 Applicable Models...............................................................................................639 Air Conditioner System..........................................................................................640 Outline.....................................................................................................640 Internal and External Filters...............................................................................641 How to check Indoor air filter..........................................................................641 How to check outdoor air filter.........................................................................641 AirConditioning System Layout..............................................................................643 Air Conditioner/Heater Circuit Diagram......................................................................644 Air Conditioner/Heater Unit.................................................................................645 Airflow Diagram.........................................................................................645 Door Open by Vent Modes.................................................................................646 Main Components.........................................................................................646 Actuator Internal/external air exchange...............................................................648 Airflow Control Module..................................................................................648 Relay Blower..............................................................................................649 Relay A/C.................................................................................................649 Duct Sensor.................................................................................................649 Water Temp Sensor...........................................................................................650 Internal Air Temp Sensor....................................................................................650 Ambient Air Temperature Sensor..............................................................................650 Sun Sensor..................................................................................................651 Control Panel...............................................................................................651 Appearance and Terminal Arrangement.....................................................................651 Terminal Terms..........................................................................................652 Control Logic...........................................................................................653 Selfdiagnosis..........................................................................................657 Ambient Temp Display....................................................................................658 Compressor..................................................................................................659 Receiver Dryer..............................................................................................659 Troubleshooting.................................................................................................660 Refrigerant Pressure Check..................................................................................660 Weight of R134a Gas Used In Machines............................................................................662 Refrigerant System Repairs......................................................................................663 Refrigerant Safe Handling Procedures........................................................................663 Repair and Replacement Procedure............................................................................664 Refrigerant Recovery........................................................................................666 Vacuuming Refrigerant System................................................................................666 Leakage Check...............................................................................................668 Refrigerant Charging........................................................................................668 Inspecting System For Leakage...............................................................................670 Electrical System...................................................................................................671 Safety Precautions..............................................................................................677 Applicable Models...............................................................................................677 Introduction....................................................................................................679 Electrical Wire Color.......................................................................................679 Electrical Supply System........................................................................................680 Engine Starting Circuit.........................................................................................682 Start Operation.............................................................................................682 After Start.................................................................................................684 Operation of the Start Circuit (2) Immediately After Start............................................685 Engine Preheating System........................................................................................686 Engine Stop.....................................................................................................688 Charging System.................................................................................................690 Monitoring System...............................................................................................691 Instrument Panel............................................................................................692 Monitoring System Schematic.................................................................................694 Operation.......................................................................................................696 Instruments.................................................................................................696 Warning and Indicator Lights....................................................................................698 Indication of Warning Lights................................................................................698 Indication of Multifunction Gauge and Letter Information Area...............................................699 Initial Operation...............................................................................................701 Mode Selector Switch............................................................................................701 Power Mode / Trenching Mode Switch..........................................................................701 Auto Idle Switch............................................................................................701 Graphic Information Area Display................................................................................702 Overview....................................................................................................702 Main Menus for the Graphic Display Area.....................................................................703 Menu Selector Buttons.......................................................................................703 Main Menu.......................................................................................................704 Language....................................................................................................704 Set Clock...................................................................................................705 Filter/Oil Info.............................................................................................705 Menu Display Order and Icon Explanation.................................................................706 Adjust Display..............................................................................................706 Set Password................................................................................................707 Special Menu....................................................................................................708 Entering/Accessing and Exiting/Escaping Menus...............................................................708 Entering/Accessing Menus................................................................................708 Exiting/Escaping Menus..................................................................................709 Special Menu Selections.....................................................................................709 Information of Machine Status...........................................................................710 Failure Information.....................................................................................714 Information of Machine Operation........................................................................722 Machine Operation Info Screen...........................................................................725 Electronic Hydraulic Control System (eEPOS)....................................................................726 Control System Schematic....................................................................................726 Power Mode Control..............................................................................................728 Operation...................................................................................................730 1. Power Mode...........................................................................................730 2. Standard Mode........................................................................................731 3) Operation in case of failure in the control system (Aux mode operation...............................731 Power Mode Control Circuit Diagram............................................................................732 Work Mode Control...............................................................................................734 Operation...................................................................................................735 1. Digging Mode.........................................................................................735 2. Trenching Mode.......................................................................................735 Work Mode Control Circuit Diagram.............................................................................736 Engine Control System...........................................................................................737 Engine Control Dial.............................................................................................738 Engine Control Circuit Diagram..................................................................................739 Automatic Deceleration Control (Auto Idle Control)..............................................................740 Engine Overheat Protection System...............................................................................742 Power Boost Mode................................................................................................744 Operation...................................................................................................744 Power Boost Control Circuit Diagram.......................................................................746 Automatic Travel Speed Control..................................................................................748 Automatic Travel Speed Control Circuit Diagram............................................................750 Selfdiagnostic Function........................................................................................751 eEPOS Controller...........................................................................................751 Wiper System....................................................................................................753 Wiper Circuit...............................................................................................753 Wiper operation.............................................................................................754 Continuous operation....................................................................................754 Intermittent operation..................................................................................754 Lighting System.................................................................................................756 Lighting System Circuit Diagram.............................................................................756 Kind of Light...............................................................................................757 Operation...................................................................................................757 Audio Controller................................................................................................758 Audio Controller Circuit Diagram............................................................................758 Operations Via Audio Control Panel......................................................................758 Electrical Schematic (DX300LL)......................................................................................759 Safety Precautions..............................................................................................763 Applicable Models...............................................................................................763 General Description.............................................................................................765 DX300LL.........................................................................................................766 Attachments.............................................................................................................769 Boom and Stick......................................................................................................771 Safety Precautions..............................................................................................775 Applicable Models...............................................................................................775 Front Attachment Pin Specifications.............................................................................776 DX300LL.....................................................................................................777 Size and Weight Specifications..............................................................................777 Front Attachment Removal and Installation.....................................................................778 Stick Removal Procedure.....................................................................................778 Boom Removal Procedure......................................................................................780 Installation....................................................................................................781 Stick Installation Procedure................................................................................781 Boom Installation Procedure.................................................................................781 Startup Procedures.............................................................................................781 Boom and Arm (Excavator Front Option)...............................................................................783 Safety Precautions..............................................................................................787 Applicable Models...............................................................................................787 Front Attachment Pin Specifications.............................................................................788 DX300LC.....................................................................................................789 Front Attachment Removal and Installation.....................................................................790 Arm Removal Procedure.......................................................................................790 Boom Removal Procedure......................................................................................793 Installation....................................................................................................794 Arm Installation Procedure..................................................................................794 Boom Installation Procedure.................................................................................794 Startup Procedures.............................................................................................794 Bucket (Excavator Front Option).....................................................................................795 Safety Precautions..............................................................................................799 Applicable Models...............................................................................................799 Bucket Tooth Inspection and Replacement.........................................................................800 Bucket Oring Replacement.......................................................................................801 Bucket Shimming Procedures......................................................................................803 New Bucket Installation.....................................................................................803 Shimming Procedures for Installed Bucket................................................................804 Bucket Attachment, Removal and Reversal.........................................................................805 Detaching the Bucket........................................................................................805 Attaching the Bucket........................................................................................805 Reversing the Bucket........................................................................................806
DOOSAN DX300LL EXCAVATOR LOG LOADER SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
R.D
