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Doosan DX225LL-5 Forestry Machine Operation & Maintenance Manual 950106-01566 – PDF DOWNLOAD
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Doosan DX225LL-5 Forestry Machine Operation & Maintenance Manual 950106-01566 – PDF DOWNLOAD
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950106-01566
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Description
Doosan DX225LL-5 Forestry Machine Operation & Maintenance Manual 950106-01566 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX225LL-5 Forestry Machine Operation & Maintenance Manual 950106-01566 – PDF DOWNLOAD
Serial Number 10001 and Up
950106-01566
Foreword:
- This Operation & Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT.
- Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment.
- Any modification made without written authorization or approval from DOOSAN can create a safety hazard. Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.
Intended Use:
- The machine is intended to be used under normal conditions for applications described in this manual. If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use.
- Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual. Contact your DOOSAN distributor for further information.
Engine and Emission Control System Maintenance:
- Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating. This includes proper inspection and maintenance of the machine’s emission control system.
- This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and/or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance.
- The required maintenance procedures are outlined in this Operation & Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system.
TABLE OF CONTENTS:
Doosan DX225LL-5 Forestry Machine Operation & Maintenance Manual 950106-01566 – PDF DOWNLOAD
DX225LL-5....................................................................................................................................................... 0 Table of Contents........................................................................................................................................... 5 Foreword.................................................................................................................................................... 9 Intended Use............................................................................................................................................ 9 Engine and Emission Control System Maintenance.......................................................................................................... 9 Machine Capacity........................................................................................................................................ 10 Product Identification Number (PIN)..................................................................................................................... 11 Component Serial Numbers............................................................................................................................ 11 Engine Identification................................................................................................................................... 12 Engine Data Plate................................................................................................................................... 12 Your Machine Serial Numbers............................................................................................................................. 12 Safety Messages......................................................................................................................................... 12 Signal Words........................................................................................................................................ 13 Other Signal Words.................................................................................................................................. 13 AEM Safety Manual (North America Only).................................................................................................................. 14 Federal and California Emission Control Systems......................................................................................................... 15 Limited Warranty for Non-road Engines (CI) (FDICL05.8LEA (DL06P))................................................................................... 15 Owner’s Warranty Rights and Obligations......................................................................................................... 15 Manufacturer's Warranty Coverage................................................................................................................ 16 Owner’s Warranty Responsibilities............................................................................................................... 16 Safety...................................................................................................................................................... 17 Safety Decals........................................................................................................................................... 18 Safety Decals With Text............................................................................................................................. 18 Safety Decals Without Text (No-Text)................................................................................................................ 19 Information and Location for Safety Decals.......................................................................................................... 20 Information and Location for Safety Decals (Continued).............................................................................................. 21 1. General Hazard (950205-03804)................................................................................................................ 22 2. Warning Tag - "Do Not Operate" (950205-03802)................................................................................................ 23 3. Keep Bystanders Away (950205-03803).......................................................................................................... 23 4. Hot Pressurized Fluid (950205-03781)......................................................................................................... 23 5. Entanglement in Rotating Parts (950205-03791)................................................................................................ 23 6. Rotating Fan (950205-03788).................................................................................................................. 24 7. Battery Explosion (950205-03785)............................................................................................................. 24 8. Battery Disconnection (950205-03784)......................................................................................................... 24 9. Flying Debris or Objects (950205-03866)...................................................................................................... 25 10. Crush Hazard (950205-03805)................................................................................................................. 25 11. Pressurized Gas and Fluid (950205-03782).................................................................................................... 25 12. Fall Hazard (950205-03783).................................................................................................................. 26 13. Hot Surface (950205-03777).................................................................................................................. 26 14. Emergency Exit (950205-03810)............................................................................................................... 26 15. ISO Control Pattern (950205-03860).......................................................................................................... 27 BHL Control Pattern (US Only) (950205-03868A)................................................................................................... 27 17. Ultra Low Sulfur Diesel Fuel (Optional) (950205-03863)...................................................................................... 27 19. Falling Object (950205-03786)............................................................................................................... 28 20. Hydraulic Oil Check (Optional) (950205-06281, 950205-03965, 950205-06282)................................................................... 29 21. Hydraulic Breaker (950205-03964)............................................................................................................ 30 22. Lift/Tie down (950205-03815)................................................................................................................ 30 23. Tie down (950205-03816)..................................................................................................................... 30 24. Electric Welding Attention (950212-02440)................................................................................................... 30 25. Do Not Lift (950205-03570).................................................................................................................. 31 26. DEF (AdBlue) (950205-01489A)................................................................................................................ 31 27. Lifting Capacity (950205-05450)............................................................................................................. 31 28. Front Control............................................................................................................................... 32 General................................................................................................................................................. 33 Safe Operation is Operator's Responsibility......................................................................................................... 33 Know Your Machine................................................................................................................................... 33 Proper Work Tools and Attachments................................................................................................................... 34 Pressurized Fluids.................................................................................................................................. 34 Flying or Falling Objects........................................................................................................................... 35 Personal Protective Equipment (PPE)................................................................................................................. 36 Correction of Machine Problems...................................................................................................................... 36 Crushing and Cutting................................................................................................................................ 36 Hot Coolant and Oils - Burn Prevention.............................................................................................................. 37 Fire and Explosion Prevention....................................................................................................................... 38 Maintenance..................................................................................................................................... 38 Operation....................................................................................................................................... 38 Electrical...................................................................................................................................... 39 Hydraulic System................................................................................................................................ 39 Fueling......................................................................................................................................... 40 Never Use Ether Starting Aids................................................................................................................... 40 Welding and Grinding............................................................................................................................ 40 If a Fire Occurs................................................................................................................................ 41 Fire Extinguisher and First-aid Kit (Emergency Medical Kit)......................................................................................... 41 Electrical System and Electrical Shock.............................................................................................................. 42 Operator Protective Guards and Structures (Optional)................................................................................................ 42 Protecting Cabin from Flying or Falling Objects (Optional)...................................................................................... 43 Emergency Exit from Operator's Station.............................................................................................................. 43 Transportation.......................................................................................................................................... 44 Obey State and Local Over-the-Road Regulations...................................................................................................... 44 Loading and Unloading............................................................................................................................... 44 Transporting Machine................................................................................................................................ 45 Operation............................................................................................................................................... 46 Before Engine Starting.............................................................................................................................. 46 Machine Condition............................................................................................................................... 46 Work Site........................................................................................................................................... 47 Mounting/Dismounting................................................................................................................................ 48 Cleaning............................................................................................................................................ 49 Operator Station.................................................................................................................................... 49 Seat Belt........................................................................................................................................... 50 Visibility Information.............................................................................................................................. 51 Work Site Rules................................................................................................................................. 52 Boost Starting or Charging Engine Batteries......................................................................................................... 52 Starting Engine..................................................................................................................................... 53 Swinging or Traveling............................................................................................................................... 54 Lifting and Logging................................................................................................................................. 56 Operation on Slopes................................................................................................................................. 57 Towing.............................................................................................................................................. 58 Attachment.......................................................................................................................................... 59 Equipment Lowering with Engine Stopped.............................................................................................................. 59 Engine Stop......................................................................................................................................... 60 Parking Machine..................................................................................................................................... 60 Preservation/Storing Machine........................................................................................................................ 61 Check After Long-term Parking................................................................................................................... 62 Maintenance............................................................................................................................................. 63 Warning Tag......................................................................................................................................... 65 Cleaning............................................................................................................................................ 66 Proper Tools and Clothing........................................................................................................................... 66 Disassembling Precautions........................................................................................................................... 66 Use of Lighting..................................................................................................................................... 66 Fire and Explosion Prevention....................................................................................................................... 67 Burn Prevention..................................................................................................................................... 68 Rubber That Contains Fluorides...................................................................................................................... 69 Rubber and Plastics................................................................................................................................. 70 Waste Hazardous to the Environment.............................................................................................................. 70 Check List After Fire........................................................................................................................... 70 Welding Repairs..................................................................................................................................... 71 Preparation for Electrical Welding on Body Structure............................................................................................ 72 Warning for Counterweight and Front Attachment Removal.............................................................................................. 72 Lock Inspection Covers.............................................................................................................................. 73 Working on Machine.................................................................................................................................. 73 Accumulator......................................................................................................................................... 74 Compressed Air...................................................................................................................................... 74 Track Tension Adjustments........................................................................................................................... 75 Supports and Blocking for Work Equipment............................................................................................................ 75 High-pressure Lines, Tubes and Hoses................................................................................................................ 76 Battery............................................................................................................................................. 77 Battery Hazard Prevention....................................................................................................................... 77 Environment and Circumstances........................................................................................................................... 79 Work Site Areas Requiring Extra Caution............................................................................................................. 79 Drop-off or Edge................................................................................................................................ 79 Poor Visibility................................................................................................................................. 79 Loose or Soft Ground............................................................................................................................ 80 High-voltage Cables................................................................................................................................. 80 Working in Water.................................................................................................................................... 81 Working in Contaminated Environment................................................................................................................. 81 Operation in Extreme Conditions..................................................................................................................... 81 Operation In Extreme Cold....................................................................................................................... 81 Operation in Extreme Heat....................................................................................................................... 83 Operation In Dusty and Sandy Areas.............................................................................................................. 84 Operation in Rainy or Humid Conditions.......................................................................................................... 84 Operation in Saltwater Areas.................................................................................................................... 85 Operation at High Altitudes..................................................................................................................... 85 Operation During Electrical Storms.............................................................................................................. 85 Exhaust Ventilation................................................................................................................................. 86 Ventilation for Enclosed Area................................................................................................................... 86 Asbestos Information................................................................................................................................ 86 Silica Dust Information............................................................................................................................. 87 Disposal of Hazardous Materials..................................................................................................................... 87 Operating Controls.......................................................................................................................................... 89 Component Locations..................................................................................................................................... 90 Operator's Area......................................................................................................................................... 94 Operational Controls and Panels......................................................................................................................... 96 1. Starter Switch................................................................................................................................... 98 2. Heater and Air Conditioner Control Panel......................................................................................................... 99 3. Power Socket for 12 Volt......................................................................................................................... 99 4. Cigarette Lighter................................................................................................................................ 99 5. Smart Power Control Switch (Road Builder Only)...................................................................................................100 6. Engine Speed Control Dial........................................................................................................................100 7. Travel Speed Selector Switch.....................................................................................................................100 8. Light Switch.....................................................................................................................................101 9. 2-Pump Flow Control Switch.......................................................................................................................101 10. Cabin Work Light Switch (Optional)..............................................................................................................101 11. Audio Control Panel.............................................................................................................................102 12. Wiper Control Panel.............................................................................................................................103 13. Quick Coupler Switch (Road Builder Only)........................................................................................................104 14. Travel/Swing Alarm Switch (Optional)............................................................................................................105 15. Power Socket for 12 Volt........................................................................................................................105 16. Horn Button (Left-hand Work Lever)..............................................................................................................105 17. Booster Button (Right-hand Work Lever)..........................................................................................................106 18. Rotating Switch.................................................................................................................................106 19. Shear Switch....................................................................................................................................106 20. Display Monitor.................................................................................................................................107 21. Photo Sensor....................................................................................................................................107 22. Safety Lever....................................................................................................................................107 23. Auxiliary Mode Switch...........................................................................................................................108 24. Hour Meter......................................................................................................................................108 25. One Touch Deceleration Button...................................................................................................................108 26. Selector Switch Control Panel...................................................................................................................109 27. Jack Assembly...................................................................................................................................111 28. Micro Phone.....................................................................................................................................111 29. DeSOx Switch....................................................................................................................................112 Display Monitor.........................................................................................................................................113 Functional Check....................................................................................................................................113 Password Activated..................................................................................................................................114 1. Fuel Gauge.......................................................................................................................................114 2. DEF (AdBlue) Level Gauge.........................................................................................................................114 3. Engine Coolant Temperature Gauge.................................................................................................................115 4. Hydraulic Oil Temperature Gauge..................................................................................................................115 5. Multifunction Gauge and Graphic Information Area.................................................................................................116 6. ECO Gauge........................................................................................................................................117 7. Trip Meter.......................................................................................................................................117 8. Digital Clock....................................................................................................................................118 9. Display Warning Symbols..........................................................................................................................118 10. Warning Light...................................................................................................................................125 11. Function Buttons................................................................................................................................126 12. Mode Selector Buttons...........................................................................................................................128 13. Selector Function Display.......................................................................................................................129 14. Jog Switch......................................................................................................................................129 15. Camera Mode Selector/ESC Button.................................................................................................................129 16. Multimedia Selector Button......................................................................................................................130 Launch Menu.........................................................................................................................................130 Warning Pop-up Window...............................................................................................................................133 Warning Pop-up Windows List.....................................................................................................................135 User Menu...............................................................................................................................................136 User Menu - Access and Escape Methods...............................................................................................................136 Access Method...................................................................................................................................136 Escape Method...................................................................................................................................136 User Menu.......................................................................................................................................136 Switch Operation Indication.........................................................................................................................167 Heater and Air Conditioner Control Panel................................................................................................................169 Location of Controls and Vents......................................................................................................................169 Control Panel.......................................................................................................................................170 1. Automatic Temperature Control Button.........................................................................................................170 2. Off Button...................................................................................................................................171 3. Temperature Control Button...................................................................................................................171 4. Temperature Unit Selector Button.............................................................................................................171 5. Mode Selector Button.........................................................................................................................171 6. Air Inlet Selector Button....................................................................................................................173 7. Fan Speed Selector Buttons...................................................................................................................173 8. Air Conditioner Button.......................................................................................................................173 9. Defroster Button.............................................................................................................................174 10. LCD Display.................................................................................................................................174 Memory Function.....................................................................................................................................174 Additional Operating Instructions...................................................................................................................174 Stereo..................................................................................................................................................175 Miscellaneous Electrical Devices........................................................................................................................176 Cabin Light.........................................................................................................................................176 Pilot Cutoff Switch.................................................................................................................................176 Circuit Breaker (80 A)..............................................................................................................................176 Circuit Breaker (30 A)..............................................................................................................................177 Fuse Boxes..........................................................................................................................................177 Seat Adjustment.........................................................................................................................................178 1. Forward/Backward Adjustment......................................................................................................................178 2. Adjusting Height of Seat and Depth of Cushion....................................................................................................178 Forward Tilt....................................................................................................................................178 Cushion Slide...................................................................................................................................178 Seat Height.....................................................................................................................................178 3. Reclining Position Adjustment....................................................................................................................179 4. Lumbar Support Adjustment........................................................................................................................179 5. Headrest.........................................................................................................................................179 6. Seat Belt........................................................................................................................................179 Seat Belt Locking and Unlocking.................................................................................................................180 7. Storage Compartment..............................................................................................................................180 8. Left and Right Control Stand Adjustment..........................................................................................................180 9. Left and Right Control Stand Height Adjustment...................................................................................................181 10. Adjusting Height/Angle of Armrest...............................................................................................................181 11. Heating Operator's Seat.........................................................................................................................181 Engine Emergency Stop Switch............................................................................................................................182 Emergency Exit Glass Breaking Tool......................................................................................................................182 Miscellaneous Convenience Devices.......................................................................................................................183 Ceiling Cover.......................................................................................................................................183 Opening Ceiling Cover...........................................................................................................................183 Closing Ceiling Cover...........................................................................................................................183 Front Windows.......................................................................................................................................184 Front Upper Window..............................................................................................................................184 Front Bottom Window.............................................................................................................................185 Door Side Latch.....................................................................................................................................186 Cabin Riser Access Door.............................................................................................................................186 Tilt Cabin..........................................................................................................................................187 Cabin Storage Compartments..........................................................................................................................188 Sunglasses Case.....................................................................................................................................188 Sun Visor...........................................................................................................................................189 Front Window Visor..............................................................................................................................189 Ceiling Window Visor............................................................................................................................189 Hanger..............................................................................................................................................190 Cup Holder..........................................................................................................................................190 Miscellaneous Access Covers and Doors...................................................................................................................191 Side Door...........................................................................................................................................191 Battery Box Door....................................................................................................................................191 Opening.........................................................................................................................................191 Closing.........................................................................................................................................191 Engine Cover........................................................................................................................................192 Operation...................................................................................................................................................193 To Operate a New Forestry Machine.......................................................................................................................193 Lubrication and Filters.............................................................................................................................194 Starting and Stopping Engine............................................................................................................................194 Inspection Before Starting Engine...................................................................................................................194 Walk Around Checks..............................................................................................................................194 Checks Before Starting Engine...................................................................................................................196 Operational Checks Before Starting Engine...........................................................................................................197 Engine Start........................................................................................................................................198 After start limit logic.........................................................................................................................200 Cold Weather Starting...............................................................................................................................200 Engine Pre-heater...............................................................................................................................200 Engine Coolant Heater (Optional)....................................................................................................................203 Plug Heater (Optional)..............................................................................................................................205 Starting Engine with a Booster Cable................................................................................................................206 Connecting Booster Batteries....................................................................................................................206 Disconnecting Booster Batteries.................................................................................................................207 Hydraulic System Warm-up............................................................................................................................207 Hydraulic System Warm-up – Cold Weather.............................................................................................................208 Stopping Engine.....................................................................................................................................210 Checks and Maintenance After Stopping Engine........................................................................................................211 Safety Lever............................................................................................................................................211 Travel..................................................................................................................................................212 Automatic Travel Speed Control......................................................................................................................212 Travel Control Lever Operation......................................................................................................................213 General Travel Instructions.........................................................................................................................214 Straight Travel Pedal (Optional)....................................................................................................................217 Operating.......................................................................................................................................217 Locking Pedal...................................................................................................................................217 Operating Instructions..................................................................................................................................219 Engine Speed Control................................................................................................................................219 Emission Control System.............................................................................................................................219 Reaction at Low Reductant Level.................................................................................................................219 Reaction to Faults in SCR System - EPA..........................................................................................................220 DeSOx...............................................................................................................................................221 Active DeSOx....................................................................................................................................222 Manual (Forced) DeSOx...........................................................................................................................223 Mode Selection......................................................................................................................................224 Power Mode......................................................................................................................................224 Work Mode.......................................................................................................................................225 Auto Idle Mode..................................................................................................................................225 Boost Mode......................................................................................................................................226 Work Levers (Joysticks) (ISO Pattern)...............................................................................................................227 Left-hand Work Lever (Joystick) (Figure 60 and Figure 61).......................................................................................227 Right-hand Work Lever (Joystick) (Figure 60 and Figure 63)......................................................................................227 Change Machine Control Pattern By Selector Valve (If Equipped)......................................................................................228 Work Levers (Joysticks) (BHL Pattern)...............................................................................................................229 Left-hand Work Lever (Joystick) (Figure 64 and Figure 66).......................................................................................229 Right-hand Work Lever (Joystick) (Figure 64 and Figure 67)......................................................................................229 Operating Precautions...................................................................................................................................230 Always Observe These Precautions....................................................................................................................232 Working in Water....................................................................................................................................233 Escaping From Mud...................................................................................................................................233 Track On One Side Stuck.........................................................................................................................233 Tracks On Both Sides Stuck......................................................................................................................233 Parking Forestry Machine................................................................................................................................234 Towing Procedure........................................................................................................................................235 Shear Operation (Optional)..........................................................................................................................236 To Activate Shear (Road Builder Only)...........................................................................................................237 Two-way Valve Operation (Optional)..................................................................................................................238 Activating Shear with Pedal Valve...............................................................................................................238 Stopper Positions...............................................................................................................................238 Rotating Operation..................................................................................................................................239 Operation Under Abnormal Conditions.....................................................................................................................240 Operation In Extreme Cold...........................................................................................................................240 Operation in Extreme Heat...........................................................................................................................241 Operation In Dusty and Sandy Areas..................................................................................................................243 Operation in Rainy or Humid Conditions..............................................................................................................243 Operation in Saltwater Areas........................................................................................................................244 Operation at High Altitudes.........................................................................................................................244 Operation During Electrical Storms..................................................................................................................244 Equipment Lowering with Engine Stopped..............................................................................................................245 Machine without a Boom Lock Valve...............................................................................................................245 Machine with a Boom Lock Valve..................................................................................................................247 Long Term Storage.......................................................................................................................................248 Before Storage......................................................................................................................................248 During Storage......................................................................................................................................249 After Storage.......................................................................................................................................249 Inspection, Maintenance and Adjustment......................................................................................................................251 Maintenance Information.................................................................................................................................251 Operational Hour Meter Reading......................................................................................................................251 DOOSAN Genuine Replacement Parts....................................................................................................................251 DOOSAN Genuine Lubricants...........................................................................................................................251 Windshield Washer Fluid.............................................................................................................................251 Fresh and Clean Lubricants..........................................................................................................................251 Check Drained Oil and Used Filter...................................................................................................................251 Fuel Strainer.......................................................................................................................................251 Welding Instructions................................................................................................................................252 Do Not Drop Things Inside Machine...................................................................................................................252 Dusty Work Site.....................................................................................................................................252 Avoid Mixing Lubricants.............................................................................................................................252 Locking Inspection Covers...........................................................................................................................252 Hydraulic System - Air Bleeding.....................................................................................................................253 Hydraulic Hose Installation.........................................................................................................................253 Checks After Inspection and Maintenance Works.......................................................................................................253 Safety Precautions..................................................................................................................................254 Machine Setup Position for Maintenance..................................................................................................................255 Maintenance Handling Access.............................................................................................................................257 Entering/Leaving/Climbing On Machine................................................................................................................257 Handling Oil, Fuel, DEF (AdBlue), Coolant...............................................................................................................258 Oil.................................................................................................................................................258 Fuel................................................................................................................................................258 DEF (AdBlue)........................................................................................................................................260 Engine Oil..........................................................................................................................................261 Grease..............................................................................................................................................261 Coolant and Water for Dilution......................................................................................................................262 Filters.............................................................................................................................................263 Electrical System Maintenance...........................................................................................................................264 Recommend Fuel, Coolant, and Lubricant..................................................................................................................265 Lubrication.........................................................................................................................................265 Symbols for "Lubrication and Service Chart".........................................................................................................266 Lubrication and Service Chart...................................................................................................................268 Fluid Capacities........................................................................................................................................271 Table of Recommended Lubricants.........................................................................................................................272 Maintenance Intervals...................................................................................................................................274 10 Hour / Daily Service.................................................................................................................................276 Grease Boom, Arm and Front Attachment Pins (for First 100 Hours)....................................................................................276 Check Engine Oil Level..............................................................................................................................276 Check for Leaks in Hydraulic System.................................................................................................................276 Check Level of Hydraulic Oil Tank...................................................................................................................277 Check for Leaks in Fuel System......................................................................................................................278 Check Fuel Level....................................................................................................................................279 Check DEF (AdBlue) Tank.............................................................................................................................280 Check Water Separator and Pre Fuel Filter (Fuel Prefilter) and Drain Water As Required..............................................................281 Check Oil Level of Swing Reduction Gear.............................................................................................................282 Clean Dust Net in Front of Oil Cooler and Radiator..................................................................................................283 Check Cooling System and Refill As Required.........................................................................................................284 Check Level of Window Washer Liquid.................................................................................................................284 Inspect Cooling Fan Blade...........................................................................................................................285 Check Air Intake System and Emission Control System Components......................................................................................285 Inspect Seat Belt for Proper Operation..............................................................................................................286 Inspect Rear View Camera for Proper Operation (If Equipped).........................................................................................286 Inspect Mirrors for Damage and Adjust and Clean as Required.........................................................................................286 Inspect Structure for Cracks and Faulty Welds.......................................................................................................286 Check Operation of All Switches and Travel Alarm (If Equipped)......................................................................................286 Check the Operation of Pilot Cutoff Switch..........................................................................................................287 Inspection and Maintenance of the Pilot Cutoff Switch...........................................................................................287 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor......................................................288 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds.....288 Check Operation of All Controls and Linkages........................................................................................................288 50 Hour / Weekly Service................................................................................................................................289 Perform All Daily Service Checks....................................................................................................................289 Grease Arm and Heel Joint Pins......................................................................................................................289 Grease Swing Bearing................................................................................................................................293 Drain Water and Sediment from Fuel Tank.............................................................................................................293 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)...................................................................293 Change Engine Oil and Filter (After First 50 Hours).................................................................................................293 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)....................................293 250 Hour / Monthly Service..............................................................................................................................294 Perform All Daily and 50 Hour Service Checks........................................................................................................294 Check Engine Fan and Alternator Belt Tension........................................................................................................294 Replace Hydraulic Oil Return Filter (After First 250 Hours).........................................................................................295 Change Pilot Filter (After First 250 Hours).........................................................................................................295 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear............................................................................295 Check Fluid Levels in Batteries.....................................................................................................................295 Inspect for Any Loose or Missing Nuts and Bolts.....................................................................................................295 Inspect Fuel System Hose Clamps.....................................................................................................................295 500 Hour / 3 Month Service..............................................................................................................................296 Perform All Daily, 50 and 250 Hour Service Checks...................................................................................................296 Grease Swing Gear and Pinion........................................................................................................................296 Change Engine Oil and Filter........................................................................................................................297 Clean Air-conditioning Outer Filter.................................................................................................................298 Check and Clean Air-conditioning Inner Filter.......................................................................................................299 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores............................................................300 Clean Outer Filter of Air Cleaner...................................................................................................................301 Change of Water Separator and Pre Fuel Filter (Fuel Prefilter)......................................................................................303 Change Main Fuel Filter.............................................................................................................................304 Fuel System Priming.............................................................................................................................304 Check Oil Level in Travel Reduction Gear (One on Each Side of Unit).................................................................................305 Change Oil in Travel Reduction Gear (One on Each Side of Unit) (After First 500 Hours)..............................................................305 Change Oil in Swing Reduction Gear (Drain and Refill After First 500 Hours).........................................................................305 1,000 Hour / 6 Month Service............................................................................................................................306 Perform All Daily, 50, 250 and 500 Hour Service Checks..............................................................................................306 Grease Swing Reduction Gear.........................................................................................................................306 Change Hydraulic Oil Tank Breather Filter...........................................................................................................306 Change Pilot Filter.................................................................................................................................308 Change Oil in Travel Reduction Gear (One on Each Side of Unit)......................................................................................309 Change Oil in Swing Reduction Gear..................................................................................................................310 Change Air-conditioning Outer Filter................................................................................................................311 Change Air-conditioning Inner Filter................................................................................................................312 Check Air Conditioner Refrigerant...................................................................................................................313 Change Fuel Cap Filter..............................................................................................................................314 Check and Adjust Engine**...........................................................................................................................315 2,000 Hour / Yearly Service.............................................................................................................................316 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks.......................................................................................316 Replace Outer and Inner Air Cleaner Filters.........................................................................................................316 Change Radiator Coolant.............................................................................................................................318 Hydraulic Oil Exchange and Suction Strainer Cleaning................................................................................................319 Check Alternator and Starter**......................................................................................................................321 Check All Rubber Antivibration Shock Mounts.........................................................................................................321 Perform and Record Results of Cycle Time Tests......................................................................................................321 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.....................................................................321 Check, Adjust Valve Clearance**.....................................................................................................................321 Check Head Bolt Torques.............................................................................................................................321 4,000 Hour / Biennial Service...........................................................................................................................322 Major Parts - Periodic Replacement..................................................................................................................322 4,500 Hour / Biennial Service...........................................................................................................................323 Change DEF (AdBlue) Filter..........................................................................................................................323 12,000 Hour / 6 Year Service............................................................................................................................326 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN)).........................................................................326 Air-conditioning System.................................................................................................................................327 Check Control Panel.................................................................................................................................327 Check Air Conditioner Hoses.........................................................................................................................327 Check Condenser.....................................................................................................................................327 Check Magnetic Clutch...............................................................................................................................327 Check Belt Tension..................................................................................................................................327 Bolt and Nut Inspection.................................................................................................................................328 Electrical System.......................................................................................................................................336 Battery.............................................................................................................................................336 Batteries in Cold Weather.......................................................................................................................336 Inspection of Battery Electrolyte Level.........................................................................................................337 Check Charging State............................................................................................................................337 Check Battery Terminals.........................................................................................................................337 Battery Replacement.............................................................................................................................337 Fuses...............................................................................................................................................338 Fuse Boxes......................................................................................................................................338 Fuse Identification.............................................................................................................................339 Engine Cooling System...................................................................................................................................340 General.............................................................................................................................................340 Types of Antifreeze.............................................................................................................................341 Antifreeze Concentration Tables.....................................................................................................................342 Table of Standards for Allowed Tap Water............................................................................................................342 Electric Viscous Fan Clutch.........................................................................................................................343 Removal and Installation of the Cooling Fan Assembly............................................................................................343 Fuel Transfer Pump (Optional)...........................................................................................................................344 Handling of Accumulator.................................................................................................................................347 Track Tension...........................................................................................................................................348 Venting and Priming Hydraulic System....................................................................................................................350 Main System Pump....................................................................................................................................350 Hydraulic Cylinders.................................................................................................................................350 Swing Motor.........................................................................................................................................351 Travel Motor........................................................................................................................................351 General Venting.....................................................................................................................................351 Maintenance in Special Conditions.......................................................................................................................352 Transportation..............................................................................................................................................353 Loading and Unloading...................................................................................................................................354 Warning for Counterweight and Front Attachment Removal..............................................................................................354 Counterweight.......................................................................................................................................354 Removal.........................................................................................................................................355 Installation....................................................................................................................................356 Lifting Machine.........................................................................................................................................360 Troubleshooting.............................................................................................................................................361 Electrical System.......................................................................................................................................361 Engine..................................................................................................................................................362 Lubrication System......................................................................................................................................366 Hydraulic System........................................................................................................................................367 Swing System............................................................................................................................................368 Travel System...........................................................................................................................................368 Cooling Fan.............................................................................................................................................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
DOOSAN DX225LL-5 FORESTRY MACHINE OPERATION & MAINTENANCE MANUAL 950106-01566 – PDF DOWNLOAD:
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