Doosan DX300LL Excavator Forestry Machine Operation & Maintenance Manual Sn5056 & Up – PDF DOWNLOAD
DESCRIPTION:
Doosan DX300LL Excavator Forestry Machine Operation & Maintenance Manual Sn5056 & Up – PDF DOWNLOAD
Serial Number 5056 and Up
950106-00280CE
SAFETY DECALS
- Safety decals are attached to the machine to alert the operator or maintenance person about potential hazards, the consequences of potential injury, and instructions and/or actions required to avoid the hazard.
- The location of the safety decals and the description of the decals are reviewed in the following section. Please become familiarized with all safety decals and their messages. Make sure that all the safety decals are in their correct location and legible.
- Clean or replace the safety decals if they are damaged, missing, or the texts and pictorials are not legible. When you clean the safety decals, use a soft cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety decals because this could loosen the adhesive that secures the decals to the machine.
- Remember, if a safety decal is attached to a part that is replaced, install a new safety decal on the replacement part.
- This machine uses safety decals with and without text. The type and number of safety decals can vary depending upon geographical regions and machine models.Safety
Decals With Text
- Safety decals with text consist of a signal word, pictorial and a text message panel. In some cases, a pictorial panel may not be part of the safety decal.
TABLE OF CONTENTS:
Doosan DX300LL Excavator Forestry Machine Operation & Maintenance Manual Sn5056 & Up – PDF DOWNLOAD
DX300LL........................................................................................................................................................ 0 Table of Contents.......................................................................................................................................... 5 Safety..................................................................................................................................................... 9 To the Operator of a DOOSAN Excavator.................................................................................................................. 9 Learn Signal Words Used with Safety Alert Symbol................................................................................................... 10 Safety Decals.......................................................................................................................................... 12 Information and Location for Safety Decals......................................................................................................... 14 Information and Location for Safety Decals (Continued)............................................................................................. 15 Summary of Safety Precautions for Lifting in Digging Mode.............................................................................................. 25 Unauthorized Modifications............................................................................................................................. 26 General Hazard Information............................................................................................................................. 26 Safety Rules....................................................................................................................................... 26 Safety Features.................................................................................................................................... 26 Inside Operator's Cabin............................................................................................................................ 27 Clothing and Personal Protective Items............................................................................................................. 27 Breathing Masks, Ear Protection May Be Required.................................................................................................... 28 Vibration Level Information........................................................................................................................ 28 Recommendations for Limiting Vibrations............................................................................................................ 28 Mounting and Dismounting........................................................................................................................... 29 Fuel, Oil and Hydraulic Fluid Fire Hazards......................................................................................................... 29 Precautions When Handling Fluids at High Temperature............................................................................................... 30 Asbestos Dust Hazard Prevention.................................................................................................................... 30 Injury from Work Equipment......................................................................................................................... 31 Fire Extinguisher and First Aid Kit................................................................................................................ 31 Protection from Falling or Flying Objects.......................................................................................................... 32 Attachment Precautions............................................................................................................................. 32 Accumulator........................................................................................................................................ 33 Indoor Ventilation................................................................................................................................. 33 Emergency Exit..................................................................................................................................... 33 Before Starting Engine................................................................................................................................. 34 Work Site Precautions.............................................................................................................................. 34 Checks Before Starting Engine...................................................................................................................... 35 Engine Starting.................................................................................................................................... 35 Before Operating Machine........................................................................................................................... 36 Seat Belt.......................................................................................................................................... 37 Machine Operation...................................................................................................................................... 38 When Swinging or Changing Direction of Travel...................................................................................................... 38 Travel Precautions................................................................................................................................. 38 Traveling on Slopes................................................................................................................................ 39 Prohibited Operations.............................................................................................................................. 40 Precautions for Operation.......................................................................................................................... 41 Avoid High-voltage Cables.......................................................................................................................... 41 Roll Over Protective Structure (ROPS).............................................................................................................. 42 ROPS Certification................................................................................................................................. 42 Operate Carefully on Snow, Ice and in Very Cold Temperatures....................................................................................... 43 Operations on Slopes............................................................................................................................... 43 Parking Machine.................................................................................................................................... 44 Never Let Anyone Ride on Attachment................................................................................................................ 44 Maintenance............................................................................................................................................ 0 Proper Tools....................................................................................................................................... 46 Use of Lighting.................................................................................................................................... 46 Fire Prevention and Explosion Prevention........................................................................................................... 46 Burn Prevention.................................................................................................................................... 47 Welding Repairs.................................................................................................................................... 48 Warning for Counterweight and Front Attachment Removal............................................................................................. 49 Precautions for Removal, Installation, and Storage of Attachments.................................................................................. 50 Precautions When Working on Machine................................................................................................................ 50 Lock Inspection Covers............................................................................................................................. 50 Prevention of Crushing and Cutting................................................................................................................. 50 Track Tension Adjustments Require Caution.......................................................................................................... 51 Supports and Blocking for Work Equipment........................................................................................................... 51 Action When Abnormality Is Found During Inspection................................................................................................. 51 Precautions with High-pressure Lines, Tubes and Hoses.............................................................................................. 52 Waste Materials.................................................................................................................................... 53 Hydraulic Cylinders, Pins and Bushings............................................................................................................. 53 Battery................................................................................................................................................ 54 Battery Hazard Prevention.......................................................................................................................... 54 Boost Starting or Charging Engine Batteries........................................................................................................ 55 Towing................................................................................................................................................. 56 Precautions When Towing............................................................................................................................ 56 Shipping and Transportation............................................................................................................................ 57 Obey State and Local Over-the-Road Regulations..................................................................................................... 57 Excavator Rated Lift Capacity Tables................................................................................................................... 58 Operating Controls......................................................................................................................................... 61 Component Locations.................................................................................................................................... 62 Operator's Area........................................................................................................................................ 64 Operational Controls and Panels........................................................................................................................ 66 1. Starter Switch.................................................................................................................................. 68 2. Heater and Air Conditioner Control Panel........................................................................................................ 68 3. Power Socket for 12 Volt........................................................................................................................ 69 4. Cigarette Lighter............................................................................................................................... 69 5. Engine Emergency Stop Switch.................................................................................................................... 69 6. Engine Speed Control Dial....................................................................................................................... 70 7. Travel Speed Selector Switch.................................................................................................................... 70 8. Light Switch.................................................................................................................................... 70 9. Cabin Work Light Switch......................................................................................................................... 71 10. Audio Control Panel............................................................................................................................ 71 11. Wiper Control Panel............................................................................................................................ 72 12. Travel/Swing Alarm Switch...................................................................................................................... 73 13. Fuel Heater Switch (Optional).................................................................................................................. 74 14. Power Socket for 12 Volt (Optional)............................................................................................................ 74 15. Horn Button (Left-hand Work Lever)............................................................................................................. 74 16. Rotating Buttons............................................................................................................................... 75 17. Grapple Buttons................................................................................................................................ 75 18. Booster Button (Right-hand Work Lever)......................................................................................................... 75 Instrument Panel....................................................................................................................................... 0 7. Charge Warning.................................................................................................................................. 81 8. Engine Oil Pressure Warning..................................................................................................................... 81 9. Engine Coolant Temperature Warning.............................................................................................................. 81 Multifunction Gauge and Graphic Information............................................................................................................ 0 Communication Error Warning........................................................................................................................ 84 Engine Speed....................................................................................................................................... 84 Battery Voltage.................................................................................................................................... 84 Mode Selector Buttons.................................................................................................................................. 88 1. Power Mode Selector Button...................................................................................................................... 88 2. Economy Mode Selector Button.................................................................................................................... 88 Setting Main Menu...................................................................................................................................... 0 2. Down Arrow Button............................................................................................................................... 91 3. Display Selector Button (ESC - Escape).......................................................................................................... 91 4. Selection Button................................................................................................................................ 91 5. Home Button..................................................................................................................................... 91 Operation Selection Display............................................................................................................................ 0 Camera Mode Selector Button........................................................................................................................101 Heater and Air Conditioner Control Panel...............................................................................................................102 Location of Controls and Vents.....................................................................................................................102 Control Panel......................................................................................................................................103 Memory Function....................................................................................................................................107 Additional Operating Instructions..................................................................................................................107 Miscellaneous Electrical Devices.......................................................................................................................109 Cabin Light........................................................................................................................................109 Pilot Cutoff Switch................................................................................................................................109 Circuit Breaker....................................................................................................................................109 Fusible Link.......................................................................................................................................110 Fuse Boxes.........................................................................................................................................110 Seat Adjustment........................................................................................................................................ 0 7. Storage Compartment.............................................................................................................................113 8. Left and Right Control Stand Adjustment.........................................................................................................113 9. Left and Right Control Stand Height Adjustment..................................................................................................113 Emergency Glass Breaking Tool..........................................................................................................................122 Operation..................................................................................................................................................125 To Handle a New Excavator..............................................................................................................................125 Lubrication and Filters............................................................................................................................126 Starting and Stopping the Engine.......................................................................................................................126 Inspection Before Starting Engine..................................................................................................................126 Operational Checks Before Starting Engine..........................................................................................................127 Starting Engine with a Booster Cable...............................................................................................................131 Hydraulic System Warm-up...........................................................................................................................133 Hydraulic System Warm-up - Cold Weather............................................................................................................134 Stopping Engine....................................................................................................................................135 Check and Confirmation After Stopping Engine.......................................................................................................136 Safety Lever...........................................................................................................................................137 Travel.................................................................................................................................................138 Automatic Travel Speed Control.....................................................................................................................139 Travel Control Lever Operation.....................................................................................................................140 General Travel Instructions........................................................................................................................141 Operating Instructions.................................................................................................................................144 Engine Speed Control...............................................................................................................................144 Mode Selection.....................................................................................................................................144 Work Levers (Joysticks) (ISO Pattern)..............................................................................................................146 Operating Precautions..................................................................................................................................148 Always Observe These Precautions...................................................................................................................150 Working in Water...................................................................................................................................151 Parking Excavator......................................................................................................................................152 Towing Procedure.......................................................................................................................................153 Lifting Objects........................................................................................................................................154 Operation Under Unusual Conditions.....................................................................................................................156 Operation In Extreme Cold..........................................................................................................................156 Operation in Extreme Heat..........................................................................................................................157 Operation in Dusty or Sandy Areas..................................................................................................................159 Operation in Rainy or Humid Conditions.............................................................................................................159 Operation in Salt Water Areas......................................................................................................................160 Operation at High Altitudes........................................................................................................................160 Inspection, Maintenance and Adjustment..................................................................................................................... 0 Preventive Maintenance................................................................................................................................. 0 Component Serial Numbers...........................................................................................................................163 Safety Precautions.................................................................................................................................163 Preliminary Work Machine Setup for Maintenance.........................................................................................................164 Table of Recommended Lubricants........................................................................................................................166 Coolant and Water for Dilution.....................................................................................................................168 Maintenance Intervals..................................................................................................................................172 10 Hour / Daily Service................................................................................................................................174 Grease Hoist, Stick and Front Attachment Pins (for first 100 hours)................................................................................174 Check Engine Oil Level.............................................................................................................................174 Check Level of Hydraulic Oil Tank..................................................................................................................175 Check for Leaks in Hydraulic System................................................................................................................176 Check Fuel Level...................................................................................................................................177 Check for Leaks in Fuel System.....................................................................................................................177 Check Oil Level of Swing Reduction Device..........................................................................................................179 Clean Dust Net in Front of Oil Cooler and Intercooler..............................................................................................180 Check Cooling System and Refill As Required........................................................................................................180 Check Level of Window Washer Liquid................................................................................................................181 Inspect Cooling Fan Blade..........................................................................................................................181 Check Air Intake System............................................................................................................................182 Inspect Seat Belt for Proper Operation.............................................................................................................182 Inspect Structure for Cracks and Faulty Welds......................................................................................................182 Check Operation of All Switches....................................................................................................................182 Check the Operation of Pilot Cutoff Switch.........................................................................................................183 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights......................................................184 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds....184 Check Operation of All Controls....................................................................................................................184 50 Hour / Weekly Service...............................................................................................................................185 Perform All Daily Service Checks...................................................................................................................185 Grease Hoist and Front Attachment Pins.............................................................................................................185 Grease Swing Bearing...............................................................................................................................191 Drain Water and Sediment from Fuel Tank............................................................................................................191 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)..................................................................191 Inspect Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers).......................................191 250 Hour / Monthly Service............................................................................................................................. 0 Check Engine Fan Belt Wear.........................................................................................................................193 Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours).........................................................................194 Replace Hydraulic Oil Return Filter (After First 250 Hours)........................................................................................194 Change Pilot Filter (After First 250 Hours)........................................................................................................194 Inspect Pins and Bushings of Front End Attachments for Signs of Wear...............................................................................194 Check Fluid Levels in Batteries....................................................................................................................194 Inspect for Any Loose or Missing Nuts and Bolts....................................................................................................194 Inspect Fuel System Hose Clamps....................................................................................................................194 500 Hour / 3 Month Service.............................................................................................................................195 Perform All Daily, 50 and 250 Hour Service Checks..................................................................................................195 Grease Swing Gear and Pinion.......................................................................................................................195 Change Engine Oil and Filter.......................................................................................................................196 Clean Air-Conditioning Outer Filter................................................................................................................197 Check and Clean Air-Conditioning Inner Filter......................................................................................................198 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core............................................................199 Change of Fuel Prefilter...........................................................................................................................202 Change Fuel Filter.................................................................................................................................203 Check Oil Level in Travel Reduction Device (One on Each Side of Unit)..............................................................................204 Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)...........................................................204 1,000 Hour / 6 Month Service...........................................................................................................................205 Perform All Daily, 50, 250 and 500 Hour Service Checks.............................................................................................205 Grease Swing Reduction Device......................................................................................................................205 Change Air Breather Filter.........................................................................................................................205 Change Air-Conditioning Outer Filter...............................................................................................................208 Change Air-Conditioning Inner Filter...............................................................................................................208 Check Air Conditioner Refrigerant..................................................................................................................209 Change Fuel Cap Filter.............................................................................................................................210 Check and Adjust Engine **.........................................................................................................................211 2,000 Hour / Yearly Service............................................................................................................................212 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks......................................................................................212 Change Swing Reduction Device Oil..................................................................................................................212 Change Oil in Travel Reduction Device (One on Each Side of Unit)...................................................................................213 Change Radiator Coolant............................................................................................................................215 Hydraulic Oil Exchange and Suction Strainer Cleaning...............................................................................................217 Check Alternator and Starter**.....................................................................................................................219 Check All Rubber Antivibration Shock Mounts........................................................................................................219 Perform and Record Results of Cycle Time Tests.....................................................................................................219 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage....................................................................219 Check, Adjust Valve Clearance **...................................................................................................................219 Check Head Bolt Torques............................................................................................................................219 4,000 Hour / Biennial Service..........................................................................................................................220 Major Parts - Periodic Replacement.................................................................................................................220 12,000 Hour / 6 Year Service...........................................................................................................................221 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)..........................................................................221 Air-Conditioning System................................................................................................................................222 Check Control Panel................................................................................................................................222 Check Air Conditioner Hoses........................................................................................................................222 Check Condenser....................................................................................................................................222 Check Magnetic Clutch..............................................................................................................................222 Check Belt Tension.................................................................................................................................222 Bolt and Nut Inspection................................................................................................................................223 Electrical System......................................................................................................................................231 Battery............................................................................................................................................231 Fuses..............................................................................................................................................233 Engine Cooling System..................................................................................................................................235 General............................................................................................................................................235 Antifreeze Concentration Tables....................................................................................................................237 Table of Standards for Allowed Tap Water...........................................................................................................237 Fuel Transfer Pump (Optional)..........................................................................................................................238 Handling of Accumulator................................................................................................................................241 Track Tension..........................................................................................................................................242 Venting and Priming Hydraulic System...................................................................................................................244 Main System Pump...................................................................................................................................244 Hydraulic Cylinders................................................................................................................................244 Swing Motor........................................................................................................................................245 Travel Motor.......................................................................................................................................245 General Venting....................................................................................................................................245 Long Term Storage......................................................................................................................................246 Before Storage.....................................................................................................................................246 During Storage.....................................................................................................................................247 After Storage......................................................................................................................................247 Maintenance in Special Conditions......................................................................................................................248 Transportation.............................................................................................................................................249 Loading and Unloading..................................................................................................................................249 Warning for Counterweight and Front Attachment Removal.............................................................................................249 Lifting Machine........................................................................................................................................253 Troubleshooting............................................................................................................................................255 Electrical System......................................................................................................................................255 Engine.................................................................................................................................................256 Hydraulic System.......................................................................................................................................258 Swing System...........................................................................................................................................259 Travel System..........................................................................................................................................259 Specification..............................................................................................................................................261 Standard Specification.................................................................................................................................261 Overall Dimensions.....................................................................................................................................262 Working Range..........................................................................................................................................264 Approximate Weight of Workload Materials...............................................................................................................265 Index......................................................................................................................................................267
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