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Doosan DX380LL-5 Excavator Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
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Doosan DX380LL-5 Excavator Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
Serial Number 10001 and Up
950106-01571
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Description
Doosan DX380LL-5 Excavator Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
DESCRIPTION:
Doosan DX380LL-5 Excavator Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
Serial Number 10001 and Up
950106-01571
Foreword
- This Operation & Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT. Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor.
- If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment. Any modification made without written authorization or approval from DOOSAN can create a safety hazard. Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.
Intended Use:
- The machine is intended to be used under normal conditions for applications described in this manual. If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use.
- Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual. Contact your DOOSAN distributor for further information.
Engine and Emission Control System Maintenance
- Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating. This includes proper inspection and maintenance of the machine’s emission control system.
- This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and/or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance.
- The required maintenance procedures are outlined in this Operation & Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system
TABLE OF CONTENTS:
Doosan DX380LL-5 Excavator Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
DX380LL-5....................................................................................................................................................... 0 Table of Contents........................................................................................................................................... 5 Foreword.................................................................................................................................................... 9 Intended Use............................................................................................................................................ 9 Engine and Emission Control System Maintenance.......................................................................................................... 9 Machine Capacity........................................................................................................................................ 10 Product Identification Number (PIN)..................................................................................................................... 10 Component Serial Numbers............................................................................................................................ 11 Engine Identification................................................................................................................................... 11 Engine Data Plate................................................................................................................................... 11 Your Machine Serial Numbers............................................................................................................................. 11 Safety Messages......................................................................................................................................... 12 Signal Words........................................................................................................................................ 12 Other Signal Words.................................................................................................................................. 13 AEM Safety Manual (North America Only).................................................................................................................. 13 Federal Emission Control Systems........................................................................................................................ 14 Emission Control System Warranty Statement.......................................................................................................... 14 General Warranty Provisions..................................................................................................................... 14 Warranty Period................................................................................................................................. 14 The Warranty on Emission-related Parts Shall be Interpreted as Follows:......................................................................... 15 Parts Covered by the Warranty................................................................................................................... 16 General Warranty Limitations.................................................................................................................... 17 Specific Warranty Exclusions.................................................................................................................... 18 Customer Support................................................................................................................................ 19 California Emission Control Warranty Statement...................................................................................................... 19 Your Warranty Rights and Obligations................................................................................................................ 19 Manufacturer's Warranty Coverage.................................................................................................................... 19 Owner's Warranty Responsibilities................................................................................................................... 20 Catalytic Converter................................................................................................................................. 20 Safety...................................................................................................................................................... 23 Safety Decals........................................................................................................................................... 24 Safety Decals With Text............................................................................................................................. 24 Safety Decals Without Text (No-Text)................................................................................................................ 25 Information and Location for Safety Decals.......................................................................................................... 26 Information and Location for Safety Decals (Continued).............................................................................................. 27 1. General Hazard (950205-05760)................................................................................................................ 28 2. Warning Tag - "Do Not Operate" (950205-03802)................................................................................................ 29 3. Keep Bystanders Away (950205-03803).......................................................................................................... 29 4. Hot Pressurized Fluid (950205-03781)......................................................................................................... 29 5. Entanglement in Rotating Parts (950205-03791)................................................................................................ 29 6. Rotating Fan (950205-03788).................................................................................................................. 30 7. Battery Explosion (950205-03785)............................................................................................................. 30 8. Battery Disconnection (950205-03784)......................................................................................................... 30 9. Flying Debris or Objects (950205-03866)...................................................................................................... 31 10. Crush Hazard (950205-03805)................................................................................................................. 31 11. Pressurized Gas and Fluid (950205-03782).................................................................................................... 31 12. Fall Hazard (950205-03783).................................................................................................................. 32 13. Hot Surface (950205-03777, 950209-03415).................................................................................................... 32 14. Emergency Exit (950205-05761)............................................................................................................... 32 15. ISO Control Pattern (950205-03860).......................................................................................................... 33 BHL Control Pattern (US Only) (950205-03868A)................................................................................................... 33 16. Front Control............................................................................................................................... 33 17. Ultra Low Sulfur Diesel Fuel (950205-03863)................................................................................................. 34 18. ROPS Warning (Optional) (950205-03861)...................................................................................................... 34 19. Falling Object (Optional) (950205-03786).................................................................................................... 34 20. Hydraulic Oil Check (950205-06281, 950205-03965, 950205-06282).............................................................................. 35 21. Hydraulic Breaker (950205-03964)............................................................................................................ 36 22. Lift/Tie down (950205-03815)................................................................................................................ 36 23. Tie down (950205-03816)..................................................................................................................... 36 24. Electric Welding Attention (950212-02440)................................................................................................... 36 25. Do Not Lift (950205-03570).................................................................................................................. 37 26. DEF (AdBlue) (950205-01489A)................................................................................................................ 37 27. Lifting Capacity (950205-05450)............................................................................................................. 37 28. Crush Harzard (950205-03787)................................................................................................................ 38 29. Cabin Tilting Warning (950205-05648)........................................................................................................ 38 General................................................................................................................................................. 39 Safe Operation is Operator's Responsibility......................................................................................................... 39 Know Your Machine................................................................................................................................... 39 Proper Work Tools and Attachments................................................................................................................... 40 Pressurized Fluids.................................................................................................................................. 40 Flying or Falling Objects........................................................................................................................... 41 Personal Protective Equipment (PPE)................................................................................................................. 42 Correction of Machine Problems...................................................................................................................... 42 Crushing and Cutting................................................................................................................................ 42 Hot Coolant and Oils - Burn Prevention.............................................................................................................. 43 Fire and Explosion Prevention....................................................................................................................... 44 Maintenance..................................................................................................................................... 44 Operation....................................................................................................................................... 44 Electrical...................................................................................................................................... 45 Hydraulic System................................................................................................................................ 45 Fueling......................................................................................................................................... 46 Never Use Ether Starting Aids................................................................................................................... 46 Welding and Grinding............................................................................................................................ 46 If a Fire Occurs................................................................................................................................ 47 Fire Extinguisher and First-aid Kit (Emergency Medical Kit)......................................................................................... 47 Electrical System and Electrical Shock.............................................................................................................. 48 Operator Protective Guards and Structures (Optional)................................................................................................ 48 Emergency Exit from Operator's Station.............................................................................................................. 48 Transportation.......................................................................................................................................... 49 Obey State and Local Over-the-Road Regulations...................................................................................................... 49 Loading and Unloading............................................................................................................................... 49 Transporting Machine................................................................................................................................ 50 Operation............................................................................................................................................... 51 Before Engine Starting.............................................................................................................................. 51 Machine Condition............................................................................................................................... 51 Work Site........................................................................................................................................... 52 Mounting/Dismounting................................................................................................................................ 53 Cleaning............................................................................................................................................ 54 Operator Station.................................................................................................................................... 54 Seat Belt........................................................................................................................................... 55 Visibility Information.............................................................................................................................. 56 Work Site Rules................................................................................................................................. 56 Boost Starting or Charging Engine Batteries......................................................................................................... 57 Starting Engine..................................................................................................................................... 58 Swinging or Traveling............................................................................................................................... 59 Lifting and Logging................................................................................................................................. 61 Operation on Slopes................................................................................................................................. 62 Towing.............................................................................................................................................. 63 Attachment.......................................................................................................................................... 64 Equipment Lowering with Engine Stopped.............................................................................................................. 64 Engine Stop......................................................................................................................................... 65 Parking Machine..................................................................................................................................... 65 Preservation/Storing Machine........................................................................................................................ 66 Check After Long-term Parking................................................................................................................... 67 Maintenance............................................................................................................................................. 68 Warning Tag......................................................................................................................................... 70 Cleaning............................................................................................................................................ 71 Proper Tools and Clothing........................................................................................................................... 71 Disassembling Precautions........................................................................................................................... 71 Use of Lighting..................................................................................................................................... 71 Fire and Explosion Prevention....................................................................................................................... 72 Burn Prevention..................................................................................................................................... 73 Rubber That Contains Fluorides...................................................................................................................... 74 Rubber and Plastics................................................................................................................................. 75 Waste Hazardous to the Environment.............................................................................................................. 75 Check List After Fire........................................................................................................................... 75 Welding Repairs..................................................................................................................................... 76 Preparation for Electrical Welding on Body Structure............................................................................................ 77 Warning for Counterweight and Front Attachment Removal.............................................................................................. 77 Lock Inspection Covers.............................................................................................................................. 78 Working on Machine.................................................................................................................................. 78 Accumulator......................................................................................................................................... 79 Compressed Air...................................................................................................................................... 79 Track Tension Adjustments........................................................................................................................... 80 Supports and Blocking for Work Equipment............................................................................................................ 80 High-pressure Lines, Tubes and Hoses................................................................................................................ 81 Battery............................................................................................................................................. 82 Battery Hazard Prevention....................................................................................................................... 82 Environment and Circumstances........................................................................................................................... 84 Work Site Areas Requiring Extra Caution............................................................................................................. 84 Drop-off or Edge................................................................................................................................ 84 Poor Visibility................................................................................................................................. 84 Loose or Soft Ground............................................................................................................................ 85 High-voltage Cables................................................................................................................................. 85 Roll-over Protective Structure (ROPS), Falling Object protective Structure (FOPS)................................................................... 86 ROPS/FOPS Certification............................................................................................................................. 87 Working in Water.................................................................................................................................... 87 Working in Contaminated Environment................................................................................................................. 87 Operation in Extreme Conditions..................................................................................................................... 88 Operation In Extreme Cold....................................................................................................................... 88 Operation in Extreme Heat....................................................................................................................... 89 Operation In Dusty and Sandy Areas.............................................................................................................. 90 Operation in Rainy or Humid Conditions.......................................................................................................... 91 Operation in Saltwater Areas.................................................................................................................... 91 Operation at High Altitudes..................................................................................................................... 92 Operation During Electrical Storms.............................................................................................................. 92 Exhaust Ventilation................................................................................................................................. 92 Ventilation for Enclosed Area................................................................................................................... 92 Asbestos Information................................................................................................................................ 93 Silica Dust Information............................................................................................................................. 93 Disposal of Hazardous Materials..................................................................................................................... 94 Operating Controls.......................................................................................................................................... 95 Component Locations..................................................................................................................................... 96 Operator's Area.........................................................................................................................................100 Operational Controls and Panels.........................................................................................................................102 1. Starter Switch...................................................................................................................................104 2. Heater and Air Conditioner Control Panel.........................................................................................................105 3. Power Socket for 12 Volt.........................................................................................................................105 4. Cigarette Lighter................................................................................................................................105 5. Engine Speed Control Dial........................................................................................................................106 6. Travel Speed Selector Switch.....................................................................................................................106 7. Light Switch.....................................................................................................................................106 8. Cabin Work Light Switch..........................................................................................................................107 9. Audio Control Panel..............................................................................................................................107 10. Wiper Switch....................................................................................................................................108 11. Washer Switch...................................................................................................................................108 12. Travel/Swing Alarm Switch.......................................................................................................................109 13. Fan Switch......................................................................................................................................109 14. Manual Operating Switch of Auto Greasing Device.................................................................................................109 15. Power Socket for 12 Volt........................................................................................................................110 16. Horn Button (Left-hand Work Lever)..............................................................................................................110 17. Booster Button (Right-hand Work Lever)..........................................................................................................110 18. Rotating Switch.................................................................................................................................111 19. Shear Switch....................................................................................................................................111 20. Display Monitor.................................................................................................................................112 21. Photo Sensor....................................................................................................................................112 22. Safety Lever....................................................................................................................................112 23. Auxiliary Mode Switch...........................................................................................................................113 24. Hour Meter......................................................................................................................................113 25. Emergency Start Mode Switch.....................................................................................................................113 26. One Touch Deceleration Button...................................................................................................................114 27. Selector Switch Control Panel...................................................................................................................114 28. Jack Assembly...................................................................................................................................116 29. Micro Phone.....................................................................................................................................116 30. Travel/Work Auxiliary Mode Selector Switch......................................................................................................117 31. Swing Brake Release Switch......................................................................................................................117 Display Monitor.........................................................................................................................................118 Functional Check....................................................................................................................................118 Password Activated..................................................................................................................................119 1. Fuel Gauge.......................................................................................................................................119 2. DEF (AdBlue) Level Gauge.........................................................................................................................119 3. Engine Coolant Temperature Gauge.................................................................................................................120 4. Hydraulic Oil Temperature Gauge..................................................................................................................120 5. Multifunction Gauge and Graphic Information Area.................................................................................................121 6. ECO Gauge........................................................................................................................................122 7. Trip Meter.......................................................................................................................................122 8. Digital Clock....................................................................................................................................123 9. Display Warning Symbols..........................................................................................................................123 10. Warning Light...................................................................................................................................129 11. Function Buttons................................................................................................................................129 12. Mode Selector Buttons...........................................................................................................................131 13. Selector Function Display.......................................................................................................................132 14. Jog Switch......................................................................................................................................132 15. Camera Mode Selector/ESC Button.................................................................................................................133 16. Multimedia Selector Button......................................................................................................................133 Launch Menu.........................................................................................................................................133 Warning Pop-up Window...............................................................................................................................136 Warning Pop-up Windows List.....................................................................................................................138 User Menu...............................................................................................................................................139 User Menu - Access and Escape Methods...............................................................................................................139 Access Method...................................................................................................................................139 Escape Method...................................................................................................................................139 User Menu.......................................................................................................................................139 Switch Operation Indication.........................................................................................................................170 Heater and Air Conditioner Control Panel................................................................................................................172 Location of Controls and Vents......................................................................................................................172 Control Panel.......................................................................................................................................173 1. Automatic Temperature Control Button.........................................................................................................173 2. Off Button...................................................................................................................................174 3. Temperature Control Button...................................................................................................................174 4. Temperature Unit Selector Button.............................................................................................................174 5. Mode Selector Button.........................................................................................................................174 6. Air Inlet Selector Button....................................................................................................................176 7. Fan Speed Selector Buttons...................................................................................................................176 8. Air Conditioner Button.......................................................................................................................176 9. Defroster Button.............................................................................................................................177 10. LCD Display.................................................................................................................................177 Memory Function.....................................................................................................................................177 Additional Operating Instructions...................................................................................................................177 Stereo..................................................................................................................................................178 Stereo..............................................................................................................................................178 Miscellaneous Electrical Devices........................................................................................................................179 Cabin Light.........................................................................................................................................179 Pilot Cutoff Switch.................................................................................................................................179 Circuit Breaker (80 A)..............................................................................................................................179 Circuit Breaker (30 A)..............................................................................................................................180 Fuse Boxes..........................................................................................................................................180 Seat Adjustment.........................................................................................................................................181 1. Forward/Backward Adjustment......................................................................................................................181 2. Adjusting Height of Seat and Depth of Cushion....................................................................................................181 Forward Tilt....................................................................................................................................181 Cushion Slide...................................................................................................................................181 Seat Height.....................................................................................................................................181 3. Reclining Position Adjustment....................................................................................................................182 4. Lumbar Support Adjustment........................................................................................................................182 5. Headrest.........................................................................................................................................182 6. Seat Belt........................................................................................................................................182 Seat Belt Locking and Unlocking.................................................................................................................183 7. Storage Compartment..............................................................................................................................183 8. Left and Right Control Stand Adjustment..........................................................................................................183 9. Left and Right Control Stand Height Adjustment...................................................................................................184 10. Adjusting Height/Angle of Armrest...............................................................................................................184 11. Heating Operator's Seat.........................................................................................................................184 Engine Emergency Stop Switch............................................................................................................................185 Miscellaneous Convenience Devices.......................................................................................................................185 Cabin Riser Access Door.............................................................................................................................185 Tilt Cabin..........................................................................................................................................186 Cabin Storage Compartments..........................................................................................................................187 Cup Holder..........................................................................................................................................187 Mirror..............................................................................................................................................188 Document Delivery Hole..............................................................................................................................188 Miscellaneous Access Covers and Doors...................................................................................................................189 Side Door...........................................................................................................................................189 Storage Box Door....................................................................................................................................189 Opening.........................................................................................................................................189 Closing.........................................................................................................................................189 Engine Cover........................................................................................................................................190 Operation...................................................................................................................................................191 To Operate a New forestry machine.......................................................................................................................191 Lubrication and Filters.............................................................................................................................192 Starting and Stopping Engine............................................................................................................................192 Inspection Before Starting Engine...................................................................................................................192 Walk Around Checks..............................................................................................................................192 Checks Before Starting Engine...................................................................................................................194 Operational Checks Before Starting Engine...........................................................................................................195 Engine Start........................................................................................................................................196 After start limit logic.........................................................................................................................198 Cold Weather Starting...............................................................................................................................198 Engine Pre-heater...............................................................................................................................198 Engine Coolant Heater (Optional)....................................................................................................................201 Overview........................................................................................................................................201 Operating and Setting...........................................................................................................................202 Plug Heater (Optional)..............................................................................................................................211 Starting Engine with a Booster Cable................................................................................................................212 Connecting Booster Batteries....................................................................................................................212 Disconnecting Booster Batteries.................................................................................................................213 Hydraulic System Warm-up............................................................................................................................213 Hydraulic System Warm-up – Cold Weather.............................................................................................................214 Stopping Engine.....................................................................................................................................216 Checks and Maintenance After Stopping Engine........................................................................................................217 Safety Lever............................................................................................................................................217 Travel..................................................................................................................................................218 Automatic Travel Speed Control......................................................................................................................218 Travel Control Lever Operation......................................................................................................................219 General Travel Instructions.........................................................................................................................220 Straight Travel Pedal (Optional)....................................................................................................................223 Operating.......................................................................................................................................223 Locking Pedal...................................................................................................................................223 Operating Instructions..................................................................................................................................225 Engine Speed Control................................................................................................................................225 Emission Control System.............................................................................................................................225 Reaction at Low Reductant Level.................................................................................................................225 Reaction to Faults in SCR System (Only EPA).....................................................................................................226 Mode Selection......................................................................................................................................227 Power Mode......................................................................................................................................227 Work Mode.......................................................................................................................................228 Auto Idle Mode..................................................................................................................................228 Boost Mode......................................................................................................................................229 Work Levers (Joysticks) (ISO Pattern)...............................................................................................................230 Left-hand Work Lever (Joystick) (Figure 93 and Figure 94).......................................................................................230 Right-hand Work Lever (Joystick) (Figure 93 and Figure 96)......................................................................................230 Change Machine Control Pattern By Selector Valve (If Equipped)......................................................................................231 Work Levers (Joysticks) (BHL Pattern)...............................................................................................................232 Left-hand Work Lever (Joystick) (Figure 97 and Figure 100)......................................................................................232 Right-hand Work Lever (Joystick) (Figure 97 and Figure 101).....................................................................................232 Operating Precautions...................................................................................................................................233 Always Observe These Precautions....................................................................................................................235 Working in Water....................................................................................................................................236 Escaping From Mud...................................................................................................................................236 Track On One Side Stuck.........................................................................................................................236 Tracks On Both Sides Stuck......................................................................................................................236 Parking forestry machine................................................................................................................................237 Towing Procedure........................................................................................................................................238 Rotating Operation..................................................................................................................................238 Operation Under Abnormal Conditions.....................................................................................................................239 Operation In Extreme Cold...........................................................................................................................239 Operation in Extreme Heat...........................................................................................................................240 Operation In Dusty and Sandy Areas..................................................................................................................242 Operation in Rainy or Humid Conditions..............................................................................................................242 Operation in Saltwater Areas........................................................................................................................243 Operation at High Altitudes.........................................................................................................................243 Operation During Electrical Storms..................................................................................................................243 Long Term Storage.......................................................................................................................................244 Before Storage......................................................................................................................................244 During Storage......................................................................................................................................245 After Storage.......................................................................................................................................245 Auto Grease System (Optional)...........................................................................................................................246 Overview............................................................................................................................................246 Location............................................................................................................................................248 Lubricants..........................................................................................................................................249 Approved Lubricants.............................................................................................................................249 Lubricant Hazards...............................................................................................................................250 Lubricant Filling...............................................................................................................................250 Filler Coupling.................................................................................................................................251 Filling Cylinder (Optional).....................................................................................................................251 Cleaning........................................................................................................................................252 Pump Display and Control Elements of Control Screen.................................................................................................253 Display and Control Elements....................................................................................................................253 Three-digit LED Display.........................................................................................................................254 LED Display.....................................................................................................................................256 Push Button Operation...........................................................................................................................256 Pump Display Mode...................................................................................................................................257 Pump Programming....................................................................................................................................259 Start Programming Mode..........................................................................................................................259 Change Lubrication Interval Times...............................................................................................................259 Configure System Monitoring.....................................................................................................................260 Change Operating Modes..........................................................................................................................261 Change Access Code..............................................................................................................................262 Programming Ranges..............................................................................................................................263 Display Ranges..................................................................................................................................263 Maintenance.........................................................................................................................................263 General Information.............................................................................................................................265 Troubleshooting.....................................................................................................................................266 Operational Malfunctions........................................................................................................................266 Recording Fault Times...........................................................................................................................268 Maintenance and Repair..........................................................................................................................268 Malfunctions on Pump Unit in Progressive System.................................................................................................269 Malfunctions on Pump Units......................................................................................................................270 Inspection, Maintenance and Adjustment......................................................................................................................273 Maintenance Information.................................................................................................................................273 Operational Hour Meter Reading......................................................................................................................273 DOOSAN Genuine Replacement Parts....................................................................................................................273 DOOSAN Genuine Lubricants...........................................................................................................................273 Windshield Washer Fluid.............................................................................................................................273 Fresh and Clean Lubricants..........................................................................................................................273 Check Drained Oil and Used Filter...................................................................................................................273 Fuel Strainer.......................................................................................................................................273 Welding Instructions................................................................................................................................274 Do Not Drop Things Inside Machine...................................................................................................................274 Dusty Work Site.....................................................................................................................................274 Avoid Mixing Lubricants.............................................................................................................................274 Locking Inspection Covers...........................................................................................................................274 Hydraulic System - Air Bleeding.....................................................................................................................275 Hydraulic Hose Installation.........................................................................................................................275 Checks After Inspection and Maintenance Works.......................................................................................................275 Safety Precautions..................................................................................................................................276 Machine Setup Position for Maintenance..................................................................................................................277 Maintenance Handling Access.............................................................................................................................279 Entering/Leaving/Climbing On Machine................................................................................................................279 Handling Oil, Fuel, DEF (AdBlue), Coolant...............................................................................................................280 Oil.................................................................................................................................................280 Fuel................................................................................................................................................280 DEF (AdBlue)........................................................................................................................................282 Grease..............................................................................................................................................283 Coolant and Water for Dilution......................................................................................................................283 Filters.............................................................................................................................................284 Electrical System Maintenance...........................................................................................................................285 Recommend Fuel, Coolant, and Lubricant..................................................................................................................286 Lubrication.........................................................................................................................................286 Symbols for "Lubrication and Service Chart".........................................................................................................287 Lubrication and Service Chart...................................................................................................................288 Fluid Capacities........................................................................................................................................291 Table of Recommended Lubricants.........................................................................................................................292 Maintenance Intervals...................................................................................................................................294 10 Hour / Daily Service.................................................................................................................................297 Grease Boom, Arm and Front Attachment Pins (for first 100 hours)....................................................................................297 Check Engine Oil Level..............................................................................................................................297 Check for Leaks in Hydraulic System.................................................................................................................297 Check Level of Hydraulic Oil Tank...................................................................................................................298 Check for Leaks in Fuel System......................................................................................................................299 Check Fuel Level....................................................................................................................................299 Check DEF (AdBlue) Tank.............................................................................................................................301 Check Water Separator and Pre Fuel Filter (Fuel Prefilter) and Drain Water As Required..............................................................302 Check Oil Level of Swing Reduction Gear.............................................................................................................303 Clean Dust Net in Front of Oil Cooler and Radiator..................................................................................................304 Oil Cooler......................................................................................................................................304 Radiator........................................................................................................................................304 Check Cooling System and Refill As Required.........................................................................................................305 Check Level of Window Washer Liquid.................................................................................................................305 Inspect Cooling Fan Blade...........................................................................................................................306 Check Air Intake System and Emission Control System Components......................................................................................306 Inspect Seat Belt for Proper Operation..............................................................................................................307 Inspect Rear View Camera for Proper Operation (If Equipped).........................................................................................307 Inspect Mirrors for Damage and Adjust and Clean as Required.........................................................................................307 Inspect Structure for Cracks and Faulty Welds.......................................................................................................307 Check Operation of All Switches and Travel Alarm (If Equipped)......................................................................................307 Check the Operation of Pilot Cutoff Switch..........................................................................................................307 Inspection and Maintenance of the Pilot Cutoff Switch...........................................................................................308 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor......................................................309 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds.....309 Check Operation of All Controls and Linkages........................................................................................................309 50 Hour / Weekly Service................................................................................................................................310 Perform All Daily Service Checks....................................................................................................................310 Grease Arm and Heel Joint Pins......................................................................................................................310 Grease Swing Bearing................................................................................................................................312 Drain Water and Sediment from Fuel Tank.............................................................................................................312 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)...................................................................313 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)....................................313 250 Hour / Monthly Service..............................................................................................................................314 Perform All Daily and 50 Hour Service Checks........................................................................................................314 Grease Boom and Arm Joint Pins......................................................................................................................314 Replace Hydraulic Oil Return Filter (After First 250 Hours).........................................................................................317 Change Pilot Filter (After First 250 Hours).........................................................................................................317 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear............................................................................317 Check Fluid Levels in Batteries.....................................................................................................................317 Inspect for Any Loose or Missing Nuts and Bolts.....................................................................................................317 Inspect Fuel System Hose Clamps.....................................................................................................................317 500 Hour / 3 Month Service..............................................................................................................................318 Perform All Daily, 50 and 250 Hour Service Checks...................................................................................................318 Grease Swing Gear and Pinion........................................................................................................................318 Change Engine Oil and Filter........................................................................................................................319 Clean Air-conditioning Outer Filter.................................................................................................................321 Check and Clean Air-conditioning Inner Filter.......................................................................................................322 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores............................................................323 Clean Outer Filter of Air Cleaner...................................................................................................................324 Change of Water Separator and Pre Fuel Filter (Fuel Prefilter)......................................................................................326 Change Main Fuel Filter.............................................................................................................................327 Bleeding Fuel System............................................................................................................................329 Cleaning the DEF (AdBlue) Tank Filler Filter........................................................................................................330 Clean Centrifugal Oil Cleaner.......................................................................................................................330 Check Oil Level in Travel Reduction Gear (One on Each Side of Unit).................................................................................333 Change Oil in Travel Reduction Gear (One on Each Side of Unit) (After First 500 Hours)..............................................................333 Change Oil in Swing Reduction Gear (Drain and Refill After First 500 Hours).........................................................................333 1,000 Hour / 6 Month Service............................................................................................................................334 Perform All Daily, 50, 250 and 500 Hour Service Checks..............................................................................................334 Grease Swing Reduction Gear.........................................................................................................................334 Change Hydraulic Oil Tank Breather Filter...........................................................................................................334 Replace Hydraulic Oil Return Filter.................................................................................................................335 Change Pilot Filter.................................................................................................................................336 Change DEF (AdBlue) Filter..........................................................................................................................337 Change DEF (AdBlue) Breather Filter.................................................................................................................337 Change Oil in Travel Reduction Gear (One on Each Side of Unit)......................................................................................338 Change Oil in Swing Reduction Gear..................................................................................................................339 Change Air-conditioning Outer Filter................................................................................................................340 Change Air-conditioning Inner Filter................................................................................................................341 Check Drive Belt....................................................................................................................................341 Check Air Conditioner Refrigerant...................................................................................................................343 Change Fuel Cap Filter..............................................................................................................................344 Check and Adjust Engine**...........................................................................................................................345 2,000 Hour / Yearly Service.............................................................................................................................346 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks.......................................................................................346 Replace Outer and Inner Air Cleaner Filters.........................................................................................................346 Check and Adjust Valve Clearance....................................................................................................................348 Change Radiator Coolant.............................................................................................................................349 Hydraulic Oil Exchange and Suction Strainer Cleaning................................................................................................351 Check Alternator and Starter**......................................................................................................................353 Check All Rubber Antivibration Shock Mounts.........................................................................................................353 Perform and Record Results of Cycle Time Tests......................................................................................................353 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.....................................................................353 Check, Adjust Valve Clearance**.....................................................................................................................353 Check Head Bolt Torques.............................................................................................................................353 4,000 Hour / Biennial Service...........................................................................................................................354 Major Parts - Periodic Replacement..................................................................................................................354 12,000 Hour / 6 Year Service............................................................................................................................355 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN)).........................................................................355 Air-conditioning System.................................................................................................................................356 Check Control Panel.................................................................................................................................356 Check Air Conditioner Hoses.........................................................................................................................356 Check Condenser.....................................................................................................................................356 Check Magnetic Clutch...............................................................................................................................356 Check Belt Tension..................................................................................................................................356 Bolt and Nut Inspection.................................................................................................................................357 Electrical System.......................................................................................................................................366 Battery.............................................................................................................................................366 Batteries in Cold Weather.......................................................................................................................366 Inspection of Battery Electrolyte Level.........................................................................................................367 Check Charging State............................................................................................................................367 Check Battery Terminals.........................................................................................................................367 Battery Replacement.............................................................................................................................367 Fuses...............................................................................................................................................368 Fuse Boxes......................................................................................................................................368 Fuse Identification.............................................................................................................................369 Engine Cooling System...................................................................................................................................370 General.............................................................................................................................................370 Types of Antifreeze.............................................................................................................................371 Antifreeze Concentration Tables.....................................................................................................................372 Table of Standards for Allowed Tap Water............................................................................................................372 Fuel Transfer Pump (Optional)...........................................................................................................................373 Handling of Accumulator.................................................................................................................................376 Track Tension...........................................................................................................................................377 Venting and Priming Hydraulic System....................................................................................................................379 Main System Pump....................................................................................................................................379 Hydraulic Cylinders.................................................................................................................................379 Swing Motor.........................................................................................................................................380 Travel Motor........................................................................................................................................380 General Venting.....................................................................................................................................380 Maintenance in Special Conditions.......................................................................................................................381 Transportation..............................................................................................................................................383 Loading and Unloading...................................................................................................................................384 Warning for Counterweight and Front Attachment Removal..............................................................................................384 Counterweight.......................................................................................................................................384 Removal.........................................................................................................................................385 Installation....................................................................................................................................386 Lifting Machine.........................................................................................................................................391 Troubleshooting.............................................................................................................................................393 Electrical System.......................................................................................................................................393 Engine..................................................................................................................................................394 Variable Geometry turbocharger (VGT)....................................................................................................................398 Lubrication System......................................................................................................................................399 Hydraulic System........................................................................................................................................400 Swing System............................................................................................................................................401 Travel System...........................................................................................................................................401 Hydraulic Fan Drive System..............................................................................................................................402 Specification...............................................................................................................................................403 Standard Specification..................................................................................................................................403 Overall Dimensions......................................................................................................................................404 Disassembled Parts, Dimension and Weight................................................................................................................406 Components..........................................................................................................................................406 Boom............................................................................................................................................406 Arm.............................................................................................................................................407 Counterweight...................................................................................................................................408 Ground Pressure.........................................................................................................................................408 Working Range...........................................................................................................................................410 Forestry Machine RATED Lift Capacity Tables.............................................................................................................412 Approximate Weight of Workload Materials................................................................................................................416 Index.......................................................................................................................................................419
DOOSAN DX380LL-5 EXCAVATOR FORESTRY MACHINE OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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