Doosan DX300LL-5 Excavator Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
DESCRIPTION:
Doosan DX300LL-5 Excavator Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
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.
Doosan DX300LL-5 Excavator Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
DX300LL-5....................................................................................................................................................... 0 Table of Contents........................................................................................................................................... 5 Foreword.................................................................................................................................................... 9 Intended Use............................................................................................................................................ 9 Engine and Emission Control System Maintenance.......................................................................................................... 9 Product Identification Number (PIN)..................................................................................................................... 0 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 25. Do Not Lift (950205-03570).................................................................................................................. 37 26. DEF (AdBlue) (950205-01489A)................................................................................................................ 37 General................................................................................................................................................. 38 Safe Operation is Operator's Responsibility......................................................................................................... 38 Know Your Machine................................................................................................................................... 38 Proper Work Tools and Attachments................................................................................................................... 39 Pressurized Fluids.................................................................................................................................. 39 Flying or Falling Objects........................................................................................................................... 40 Personal Protective Equipment (PPE)................................................................................................................. 41 Correction of Machine Problems...................................................................................................................... 41 Crushing and Cutting................................................................................................................................ 41 Hot Coolant and Oils - Burn Prevention.............................................................................................................. 42 Fire and Explosion Prevention....................................................................................................................... 43 Maintenance..................................................................................................................................... 43 Operation....................................................................................................................................... 43 Electrical...................................................................................................................................... 44 Hydraulic System................................................................................................................................ 44 Fueling......................................................................................................................................... 45 Never Use Ether Starting Aids................................................................................................................... 45 Welding and Grinding............................................................................................................................ 45 If a Fire Occurs................................................................................................................................ 46 Fire Extinguisher and First-aid Kit (Emergency Medical Kit)......................................................................................... 46 Electrical System and Electrical Shock.............................................................................................................. 47 Operator Protective Guards and Structures (Optional)................................................................................................ 47 Emergency Exit from Operator's Station.......................................................................................................... 47 Transportation.......................................................................................................................................... 48 Obey State and Local Over-the-Road Regulations...................................................................................................... 48 Loading and Unloading............................................................................................................................... 48 Transporting Machine................................................................................................................................ 49 Operation............................................................................................................................................... 50 Before Engine Starting.............................................................................................................................. 50 Machine Condition............................................................................................................................... 50 Work Site........................................................................................................................................... 51 Mounting/Dismounting................................................................................................................................ 52 Cleaning............................................................................................................................................ 53 Operator Station.................................................................................................................................... 53 Seat Belt........................................................................................................................................... 54 Visibility Information.............................................................................................................................. 55 Work Site Rules................................................................................................................................. 55 Boost Starting or Charging Engine Batteries......................................................................................................... 56 Swinging or Traveling............................................................................................................................... 58 Lifting and Logging................................................................................................................................. 60 Operation on Slopes................................................................................................................................. 61 Towing.............................................................................................................................................. 62 Attachment.......................................................................................................................................... 63 Equipment Lowering with Engine Stopped.............................................................................................................. 63 Engine Stop......................................................................................................................................... 64 Parking Machine..................................................................................................................................... 64 Preservation/Storing Machine........................................................................................................................ 65 Check After Long-term Parking................................................................................................................... 66 Maintenance............................................................................................................................................. 67 Cleaning............................................................................................................................................ 70 Proper Tools and Clothing........................................................................................................................... 70 Disassembling Precautions........................................................................................................................... 70 Use of Lighting..................................................................................................................................... 70 Fire and Explosion Prevention....................................................................................................................... 71 Burn Prevention..................................................................................................................................... 72 Rubber That Contains Fluorides...................................................................................................................... 73 Rubber and Plastics................................................................................................................................. 74 Waste Hazardous to the Environment.............................................................................................................. 74 Check List After Fire........................................................................................................................... 74 Welding Repairs..................................................................................................................................... 75 Preparation for Electrical Welding on Body Structure............................................................................................ 75 Warning for Counterweight and Front Attachment Removal.............................................................................................. 76 Lock Inspection Covers.............................................................................................................................. 77 Working on Machine.................................................................................................................................. 77 Accumulator......................................................................................................................................... 78 Compressed Air...................................................................................................................................... 78 Track Tension Adjustments........................................................................................................................... 79 Supports and Blocking for Work Equipment............................................................................................................ 79 High-pressure Lines, Tubes and Hoses................................................................................................................ 80 Battery............................................................................................................................................. 81 Battery Hazard Prevention....................................................................................................................... 81 Environment and Circumstances........................................................................................................................... 83 Work Site Areas Requiring Extra Caution............................................................................................................. 83 Digging Under an Overhang....................................................................................................................... 83 Deep Digging.................................................................................................................................... 83 Drop-off or Edge................................................................................................................................ 84 Poor Visibility................................................................................................................................. 84 Loose or Soft Ground............................................................................................................................ 84 High-voltage Cables................................................................................................................................. 85 Underground Operation............................................................................................................................... 86 Working in Water.................................................................................................................................... 86 Working in Contaminated Environment................................................................................................................. 86 Operation in Extreme Conditions..................................................................................................................... 87 Operation In Extreme Cold....................................................................................................................... 87 Operation in Extreme Heat....................................................................................................................... 88 Operation In Dusty and Sandy Areas.............................................................................................................. 89 Operation in Rainy or Humid Conditions.......................................................................................................... 90 Operation in Saltwater Areas.................................................................................................................... 90 Operation at High Altitudes..................................................................................................................... 91 Operation During Electrical Storms.............................................................................................................. 91 Exhaust Ventilation................................................................................................................................. 91 Ventilation for Enclosed Area................................................................................................................... 91 Asbestos Information................................................................................................................................ 92 Silica Dust Information............................................................................................................................. 92 Disposal of Hazardous Materials..................................................................................................................... 93 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 Control Panel.............................................................................................................................108 11. Travel/Swing Alarm Switch.......................................................................................................................109 12. 2-Pump Flow Control Switch......................................................................................................................110 13. Power Socket for 12 Volt (Optional).............................................................................................................110 14. Horn Button (Left-hand Work Lever)..............................................................................................................110 15. Booster Button (Right-hand Work Lever)..........................................................................................................111 16. Rotating Switch.................................................................................................................................111 17. Shear Switch....................................................................................................................................111 18. Display Monitor.................................................................................................................................112 19. Photo Sensor....................................................................................................................................112 20. Safety Lever....................................................................................................................................112 21. Auxiliary Mode Switch...........................................................................................................................113 22. Hour Meter......................................................................................................................................113 23. Emergency Start Mode Switch.....................................................................................................................113 24. One Touch Deceleration Button...................................................................................................................114 25. Selector Switch Control Panel...................................................................................................................114 26. Jack Assembly...................................................................................................................................116 27. Micro Phone (Optional)..........................................................................................................................116 Display Monitor.........................................................................................................................................117 Functional Check....................................................................................................................................117 Password Activated..................................................................................................................................118 1. Fuel Gauge.......................................................................................................................................118 2. DEF (AdBlue) Level Gauge.........................................................................................................................118 3. Engine Coolant Temperature Gauge.................................................................................................................119 4. Hydraulic Oil Temperature Gauge..................................................................................................................119 5. Multifunction Gauge and Graphic Information Area.................................................................................................120 6. ECO Gauge........................................................................................................................................121 7. Trip Meter.......................................................................................................................................121 8. Digital Clock....................................................................................................................................122 9. Display Warning Symbols..........................................................................................................................122 10. Warning Light...................................................................................................................................128 11. Function Buttons................................................................................................................................129 12. Mode Selector Buttons...........................................................................................................................131 13. Selector Function Display.......................................................................................................................132 14. Jog Switch......................................................................................................................................132 15. Camera Mode Selector/ESC Button.................................................................................................................132 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.........................................................................................................................169 Heater and Air Conditioner Control Panel................................................................................................................171 Location of Controls and Vents......................................................................................................................171 Control Panel.......................................................................................................................................172 1. Automatic Temperature Control Button.........................................................................................................172 2. Off Button...................................................................................................................................173 3. Temperature Control Button...................................................................................................................173 4. Temperature Unit Selector Button.............................................................................................................173 5. Mode Selector Button.........................................................................................................................173 6. Air Inlet Selector Button....................................................................................................................175 7. Fan Speed Selector Buttons...................................................................................................................175 8. Air Conditioner Button.......................................................................................................................175 9. Defroster Button.............................................................................................................................176 10. LCD Display.................................................................................................................................176 Memory Function.....................................................................................................................................176 Additional Operating Instructions...................................................................................................................176 Miscellaneous Electrical Devices........................................................................................................................178 Cabin Light.........................................................................................................................................178 Pilot Cutoff Switch.................................................................................................................................178 Circuit Breaker (80 A)..............................................................................................................................178 Circuit Breaker (30 A)..............................................................................................................................179 Fuse Boxes..........................................................................................................................................179 Seat Adjustment......................................................................................................................................... 0 6. Seat Belt........................................................................................................................................ 0 Seat Belt Locking and Unlocking.................................................................................................................182 7. Storage Compartment..............................................................................................................................182 8. Left and Right Control Stand Adjustment..........................................................................................................182 Engine Emergency Stop Switch............................................................................................................................184 Emergency Exit Glass Breaking Tool......................................................................................................................184 Miscellaneous Convenience Devices....................................................................................................................... 0 Front Windows.......................................................................................................................................186 Front Upper Window..............................................................................................................................186 Door Side Latch.....................................................................................................................................188 Cabin Riser Access Door.............................................................................................................................188 Tilt Cabin..........................................................................................................................................189 Cabin Storage Compartments..........................................................................................................................190 Sunglasses Case.....................................................................................................................................190 Sun Visor...........................................................................................................................................191 Front Window Visor..............................................................................................................................191 Ceiling Window Visor............................................................................................................................191 Miscellaneous Access Covers and Doors...................................................................................................................193 Side Door...........................................................................................................................................193 Storage Box Door....................................................................................................................................193 Opening.........................................................................................................................................193 Closing.........................................................................................................................................193 Engine Cover........................................................................................................................................194 Operation...................................................................................................................................................195 To Operate a New forestry machine.......................................................................................................................195 Lubrication and Filters.............................................................................................................................196 Starting and Stopping Engine............................................................................................................................196 Inspection Before Starting Engine...................................................................................................................196 Walk Around Checks..............................................................................................................................196 Checks Before Starting Engine...................................................................................................................197 Operational Checks Before Starting Engine...........................................................................................................199 Engine Start........................................................................................................................................200 After start limit logic.........................................................................................................................202 Cold Weather Starting...............................................................................................................................202 Engine Pre-heater...............................................................................................................................202 Engine Coolant Heater (Optional)....................................................................................................................205 Plug Heater (Optional)..............................................................................................................................207 Starting Engine with a Booster Cable................................................................................................................208 Connecting Booster Batteries....................................................................................................................208 Disconnecting Booster Batteries.................................................................................................................209 Hydraulic System Warm-up............................................................................................................................209 Hydraulic System Warm-up - Cold Weather.............................................................................................................210 Stopping Engine.....................................................................................................................................212 Checks and Maintenance After Stopping Engine........................................................................................................213 Safety Lever............................................................................................................................................213 Travel..................................................................................................................................................214 Automatic Travel Speed Control......................................................................................................................214 Travel Control Lever Operation......................................................................................................................215 General Travel Instructions.........................................................................................................................216 Straight Travel Pedal (Optional)....................................................................................................................219 Operating.......................................................................................................................................219 Locking Pedal...................................................................................................................................219 Operating Instructions..................................................................................................................................221 Engine Speed Control................................................................................................................................221 Emission Control System.............................................................................................................................221 Reaction at Low Reductant Level.................................................................................................................221 Reaction to Faults in SCR System (Only EPA).....................................................................................................222 Mode Selection......................................................................................................................................223 Power Mode......................................................................................................................................223 Work Mode.......................................................................................................................................224 Auto Idle Mode..................................................................................................................................224 Boost Mode......................................................................................................................................225 Work Levers (Joysticks) (ISO Pattern)...............................................................................................................226 Left-hand Work Lever (Joystick) (Figure 59 and Figure 60).......................................................................................226 Right-hand Work Lever (Joystick) (Figure 59 and Figure 62)......................................................................................226 Work Levers (Joysticks) (BHL Pattern)...............................................................................................................228 Left-hand Work Lever (Joystick) (Figure 63 and Figure 65).......................................................................................228 Right-hand Work Lever (Joystick) (Figure 63 and Figure 66)......................................................................................228 Operating Precautions...................................................................................................................................229 Always Observe These Precautions....................................................................................................................231 Working in Water....................................................................................................................................232 Escaping From Mud...................................................................................................................................232 Track On One Side Stuck.........................................................................................................................232 Tracks On Both Sides Stuck......................................................................................................................232 Towing Procedure........................................................................................................................................234 Rotating Operation..................................................................................................................................234 Operation Under Abnormal Conditions.....................................................................................................................235 Operation In Extreme Cold...........................................................................................................................235 Operation in Extreme Heat...........................................................................................................................236 Operation In Dusty and Sandy Areas..................................................................................................................238 Operation in Rainy or Humid Conditions..............................................................................................................238 Operation in Saltwater Areas........................................................................................................................239 Operation at High Altitudes.........................................................................................................................239 Operation During Electrical Storms..................................................................................................................239 Long Term Storage.......................................................................................................................................240 Before Storage......................................................................................................................................240 During Storage......................................................................................................................................241 After Storage.......................................................................................................................................241 Inspection, Maintenance and Adjustment......................................................................................................................243 Maintenance Information.................................................................................................................................243 Operational Hour Meter Reading......................................................................................................................243 DOOSAN Genuine Replacement Parts....................................................................................................................243 DOOSAN Genuine Lubricants...........................................................................................................................243 Windshield Washer Fluid.............................................................................................................................243 Fresh and Clean Lubricants..........................................................................................................................243 Check Drained Oil and Used Filter...................................................................................................................243 Fuel Strainer.......................................................................................................................................243 Welding Instructions................................................................................................................................244 Do Not Drop Things Inside Machine...................................................................................................................244 Dusty Work Site.....................................................................................................................................244 Avoid Mixing Lubricants.............................................................................................................................244 Locking Inspection Covers...........................................................................................................................244 Hydraulic System - Air Bleeding.....................................................................................................................245 Hydraulic Hose Installation.........................................................................................................................245 Checks After Inspection and Maintenance Works.......................................................................................................245 Safety Precautions..................................................................................................................................246 Machine Setup Position for Maintenance..................................................................................................................247 Maintenance Handling Access.............................................................................................................................249 Entering/Leaving/Climbing On Machine................................................................................................................249 Handling Oil, Fuel, DEF (AdBlue), Coolant...............................................................................................................250 Oil.................................................................................................................................................250 Fuel................................................................................................................................................250 DEF (AdBlue)........................................................................................................................................252 Grease..............................................................................................................................................253 Coolant and Water for Dilution......................................................................................................................253 Filters.............................................................................................................................................254 Electrical System Maintenance...........................................................................................................................255 Recommend Fuel, Coolant, and Lubricant..................................................................................................................256 Lubrication.........................................................................................................................................256 Symbols for "Lubrication and Service Chart".........................................................................................................257 Fluid Capacities........................................................................................................................................261 Table of Recommended Lubricants.........................................................................................................................262 Maintenance Intervals...................................................................................................................................264 10 Hour / Daily Service.................................................................................................................................267 Grease Boom, Arm and Front Attachment Pins (for first 100 hours)....................................................................................267 Check Engine Oil Level..............................................................................................................................267 Check for Leaks in Hydraulic System.................................................................................................................267 Check Level of Hydraulic Oil Tank...................................................................................................................268 Check for Leaks in Fuel System......................................................................................................................269 Check Fuel Level....................................................................................................................................269 Check DEF (AdBlue) Tank.............................................................................................................................271 Check Water Separator & Pre Fuel Filter (Fuel Prefilter) and Drain Water As Required................................................................272 Check Oil Level of Swing Reduction Gear.............................................................................................................273 Clean Dust Net in Front of Oil Cooler and Radiator..................................................................................................274 Oil Cooler......................................................................................................................................274 Radiator........................................................................................................................................274 Check Cooling System and Refill As Required.........................................................................................................275 Check Level of Window Washer Liquid.................................................................................................................275 Inspect Cooling Fan Blade...........................................................................................................................276 Check Air Intake System and Emission Control System Components......................................................................................276 Inspect Seat Belt for Proper Operation..............................................................................................................277 Inspect Rear View Camera for Proper Operation (If Equipped).........................................................................................277 Inspect Mirrors for Damage and Adjust and Clean as Required.........................................................................................277 Inspect Structure for Cracks and Faulty Welds.......................................................................................................277 Check Operation of All Switches and Travel Alarm (If Equipped)......................................................................................277 Check the Operation of Pilot Cutoff Switch..........................................................................................................277 Inspection and Maintenance of the Pilot Cutoff Switch...........................................................................................278 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor......................................................279 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds.....279 Check Operation of All Controls and Linkages........................................................................................................279 50 Hour / Weekly Service................................................................................................................................280 Perform All Daily Service Checks....................................................................................................................280 Grease Arm and Heel Joint Pins......................................................................................................................280 Grease Swing Bearing................................................................................................................................284 Drain Water and Sediment from Fuel Tank.............................................................................................................284 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)...................................................................284 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)....................................284 250 Hour / Monthly Service..............................................................................................................................285 Perform All Daily and 50 Hour Service Checks........................................................................................................285 Replace Hydraulic Oil Return Filter (After First 250 Hours).........................................................................................285 Change Pilot Filter (After First 250 Hours).........................................................................................................285 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear............................................................................285 Check Fluid Levels in Batteries.....................................................................................................................285 Inspect for Any Loose or Missing Nuts and Bolts.....................................................................................................285 Inspect Fuel System Hose Clamps.....................................................................................................................285 500 Hour / 3 Month Service..............................................................................................................................286 Perform All Daily, 50 and 250 Hour Service Checks...................................................................................................286 Grease Swing Gear and Pinion........................................................................................................................286 Change Engine Oil and Filter........................................................................................................................287 Clean Air-conditioning Outer Filter.................................................................................................................289 Check and Clean Air-conditioning Inner Filter.......................................................................................................290 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores............................................................291 Clean Outer Filter of Air Cleaner...................................................................................................................292 Change of Water Separator & Pre Fuel Filter (Fuel Prefilter)........................................................................................294 Change Main Fuel Filter.............................................................................................................................295 Bleeding Fuel System............................................................................................................................297 Check Oil Level in Travel Reduction Gear (One on Each Side of Unit).................................................................................298 Change Oil in Travel Reduction Gear (One on Each Side of Unit) (After First 500 Hours)..............................................................298 Change Oil in Swing Reduction Gear (Drain and Refill After First 500 Hours).........................................................................298 1,000 Hour / 6 Month Service............................................................................................................................299 Perform All Daily, 50, 250 and 500 Hour Service Checks..............................................................................................299 Grease Swing Reduction Gear.........................................................................................................................299 Change Hydraulic Oil Tank Breather Filter...........................................................................................................299 Change Pilot Filter.................................................................................................................................301 Change DEF (AdBlue) Filter..........................................................................................................................302 Change DEF(AdBlue) Breather Filter..................................................................................................................302 Change Oil in Travel Reduction Gear (One on Each Side of Unit)......................................................................................303 Change Oil in Swing Reduction Gear..................................................................................................................304 Change Air-conditioning Outer Filter................................................................................................................305 Change Air-conditioning Inner Filter................................................................................................................306 Check Drive Belt....................................................................................................................................306 Check Air Conditioner Refrigerant...................................................................................................................308 Change Fuel Cap Filter..............................................................................................................................309 Check and Adjust Engine**...........................................................................................................................310 2,000 Hour / Yearly Service............................................................................................................................. 0 Check and Adjust Valve Clearance....................................................................................................................313 Clean Centrifugal Oil Cleaner.......................................................................................................................314 Change Radiator Coolant.............................................................................................................................316 Hydraulic Oil Exchange and Suction Strainer Cleaning................................................................................................318 Check Alternator and Starter**......................................................................................................................320 Check All Rubber Antivibration Shock Mounts.........................................................................................................320 Perform and Record Results of Cycle Time Tests......................................................................................................320 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.....................................................................320 Check, Adjust Valve Clearance**.....................................................................................................................320 Check Head Bolt Torques.............................................................................................................................320 4,000 Hour / Biennial Service...........................................................................................................................321 Major Parts - Periodic Replacement..................................................................................................................321 12,000 Hour / 6 Year Service............................................................................................................................322 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN)).........................................................................322 Air-conditioning System.................................................................................................................................323 Check Control Panel.................................................................................................................................323 Check Air Conditioner Hoses.........................................................................................................................323 Check Condenser.....................................................................................................................................323 Check Magnetic Clutch...............................................................................................................................323 Check Belt Tension..................................................................................................................................323 Bolt and Nut Inspection.................................................................................................................................324 Electrical System.......................................................................................................................................332 Battery.............................................................................................................................................332 Batteries in Cold Weather.......................................................................................................................332 Inspection of Battery Electrolyte Level.........................................................................................................333 Check Charging State............................................................................................................................333 Check Battery Terminals.........................................................................................................................333 Battery Replacement.............................................................................................................................333 Fuses...............................................................................................................................................334 Fuse Boxes......................................................................................................................................334 Fuse Identification.............................................................................................................................335 Engine Cooling System...................................................................................................................................336 General.............................................................................................................................................336 Types of Antifreeze.............................................................................................................................337 Antifreeze Concentration Tables.....................................................................................................................338 Table of Standards for Allowed Tap Water............................................................................................................338 Fuel Transfer Pump (Optional)...........................................................................................................................339 Handling of Accumulator.................................................................................................................................342 Track Tension...........................................................................................................................................343 Venting and Priming Hydraulic System....................................................................................................................345 Main System Pump....................................................................................................................................345 Hydraulic Cylinders.................................................................................................................................345 Swing Motor.........................................................................................................................................346 Travel Motor........................................................................................................................................346 General Venting.....................................................................................................................................346 Maintenance in Special Conditions.......................................................................................................................347 Transportation..............................................................................................................................................349 Loading and Unloading...................................................................................................................................350 Warning for Counterweight and Front Attachment Removal..............................................................................................350 Counterweight.......................................................................................................................................350 Removal.........................................................................................................................................351 Installation....................................................................................................................................352 Troubleshooting.............................................................................................................................................359 Electrical System.......................................................................................................................................359 Engine..................................................................................................................................................360 Variable Geometry turbocharger (VGT)....................................................................................................................364 Lubrication System......................................................................................................................................365 Hydraulic System........................................................................................................................................366 Swing System............................................................................................................................................367 Travel System...........................................................................................................................................367 Hydraulic Fan Drive System..............................................................................................................................368 Specification...............................................................................................................................................369 Standard Specification..................................................................................................................................369 Overall Dimensions......................................................................................................................................370 Disassembled Parts, Dimension and Weight................................................................................................................372 Components..........................................................................................................................................372 Boom............................................................................................................................................372 Arm.............................................................................................................................................373 Counterweight...................................................................................................................................374 Ground Pressure.........................................................................................................................................374 Working Range...........................................................................................................................................375 Forestry Machine RATED Lift Capacity Tables.............................................................................................................376 Approximate Weight of Workload Materials................................................................................................................380 Index.......................................................................................................................................................383
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