Doosan DX225LL Excavator Log loader Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD

Description

Doosan DX225LL Excavator Log loader Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Doosan DX225LL Excavator Log loader Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD

• 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 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 DX225LL Excavator Log loader Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD

DX225LL........................................................................................................................................................  0
	Table of Contents..........................................................................................................................................  5
	Safety.....................................................................................................................................................  9
		To the Operator of a DOOSAN Forest Machine.............................................................................................................  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.................................................................................................................................... 27
			Inside Operator's Cabin............................................................................................................................ 27
			Clothing and Personal Protective Items............................................................................................................. 28
			Breathing Masks, Ear Protection May Be Required.................................................................................................... 28
			Vibration Level Information........................................................................................................................ 28
			Recommendations for Limiting Vibrations............................................................................................................ 29
			Mounting and Dismounting........................................................................................................................... 30
			Fuel, Oil and Hydraulic Fluid Fire Hazards......................................................................................................... 30
			Precautions When Handling Fluids at High Temperature............................................................................................... 31
			Asbestos Dust Hazard Prevention.................................................................................................................... 31
			Injury from Work Equipment......................................................................................................................... 32
			Fire Extinguisher and First Aid Kit................................................................................................................ 32
			Protection from Falling or Flying Objects.......................................................................................................... 33
			Attachment Precautions............................................................................................................................. 33
			Accumulator........................................................................................................................................ 34
			Indoor Ventilation................................................................................................................................. 34
			Emergency Exit..................................................................................................................................... 34
		Before Starting Engine................................................................................................................................. 35
			Work Site Precautions.............................................................................................................................. 35
			Checks Before Starting Engine...................................................................................................................... 36
			Engine Starting.................................................................................................................................... 37
			Before Operating Machine........................................................................................................................... 38
			Seat Belt.......................................................................................................................................... 39
		Machine Operation...................................................................................................................................... 40
			When Swinging or Changing Direction of Travel...................................................................................................... 40
			Travel Precautions................................................................................................................................. 41
			Traveling on Slopes................................................................................................................................ 42
			Prohibited Operations.............................................................................................................................. 42
			Precautions for Operation.......................................................................................................................... 43
			Avoid High-voltage Cables.......................................................................................................................... 44
			Roll Over Protective Structure (ROPS).............................................................................................................. 45
			ROPS Certification................................................................................................................................. 45
			Operate Carefully on Snow, Ice and in Very Cold Temperatures....................................................................................... 46
			Operations on Slopes............................................................................................................................... 46
			Parking Machine.................................................................................................................................... 47
			Never Let Anyone Ride on Attachment................................................................................................................ 47
		Maintenance............................................................................................................................................  0
			Proper Tools....................................................................................................................................... 49
			Use of Lighting.................................................................................................................................... 49
			Fire Prevention and Explosion Prevention........................................................................................................... 49
			Burn Prevention.................................................................................................................................... 50
			Welding Repairs.................................................................................................................................... 51
			Warning for Counterweight and Front Attachment Removal............................................................................................. 52
			Precautions for Removal, Installation, and Storage of Attachments.................................................................................. 53
			Precautions When Working on Machine................................................................................................................ 53
			Lock Inspection Covers............................................................................................................................. 53
			Prevention of Crushing and Cutting................................................................................................................. 53
			Track Tension Adjustments Require Caution.......................................................................................................... 54
			Supports and Blocking for Work Equipment........................................................................................................... 54
			Action When Abnormality Is Found During Inspection................................................................................................. 54
			Precautions with High-pressure Lines, Tubes and Hoses.............................................................................................. 55
			Waste Materials.................................................................................................................................... 55
			Hydraulic Cylinders, Pins and Bushings............................................................................................................. 56
		Battery................................................................................................................................................ 57
			Battery Hazard Prevention.......................................................................................................................... 57
			Boost Starting or Charging Engine Batteries........................................................................................................ 58
		Towing................................................................................................................................................. 59
			Precautions When Towing............................................................................................................................ 59
		Shipping and Transportation............................................................................................................................ 60
			Obey State and Local Over-the-Road Regulations..................................................................................................... 60
		Forest Machine Rated Lift Capacity Tables.............................................................................................................. 61
	Operating Controls......................................................................................................................................... 65
		Component Locations.................................................................................................................................... 66
		Operator's Area........................................................................................................................................ 68
		Operational Controls and Panels........................................................................................................................ 70
			1. Starter Switch.................................................................................................................................. 72
			2. Heater and Air Conditioner Control Panel........................................................................................................ 72
			3. Power Socket For 12 Volt........................................................................................................................ 73
			4. Cigarette Lighter............................................................................................................................... 73
			5. Engine Emergency Stop Switch.................................................................................................................... 73
			6. Engine Speed Control Dial....................................................................................................................... 74
			7. Travel Speed Selector Switch.................................................................................................................... 74
			8. Light Switch.................................................................................................................................... 74
			9. Cabin Work Light Switch......................................................................................................................... 75
			10. Audio Control Panel............................................................................................................................ 75
			11. Wiper Control Panel............................................................................................................................ 76
			12. Travel/Swing Alarm Switch...................................................................................................................... 77
			13. Fuel Heater Switch (Optional).................................................................................................................. 78
			14. Power Socket For 12 Volt (Optional)............................................................................................................ 78
			15. Horn Button (Left-hand Work Lever)............................................................................................................. 78
			16. Rotating Buttons............................................................................................................................... 79
			17. Grapple Buttons................................................................................................................................ 79
			18. Booster Button (Right-hand Work Lever)......................................................................................................... 79
		Instrument Panel.......................................................................................................................................  0
			7. Charge Warning.................................................................................................................................. 85
			8. Engine Oil Pressure Warning..................................................................................................................... 85
			12. Work Light Indicator........................................................................................................................... 87
			13. Warning Light.................................................................................................................................. 87
		Multifunction Gauge and Graphic Information............................................................................................................  0
			Communication Error Warning........................................................................................................................ 89
			Engine Speed....................................................................................................................................... 89
			Battery Voltage.................................................................................................................................... 89
		Mode Selector Buttons.................................................................................................................................. 93
			1. Power Mode Selector Button...................................................................................................................... 93
			2. Economy Mode Selector Button.................................................................................................................... 93
			3. Auto Idle Selector Button....................................................................................................................... 94
			4. Flow Control Button (Not Used).................................................................................................................. 94
		Operation Selection Display............................................................................................................................  0
			Camera Mode Selector Button........................................................................................................................106
		Heater and Air Conditioner Control Panel...............................................................................................................107
			Location of Controls and Vents.....................................................................................................................107
			Control Panel......................................................................................................................................108
			Memory Function....................................................................................................................................112
			Additional Operating Instructions..................................................................................................................112
		Miscellaneous Electrical Devices.......................................................................................................................114
			Cabin Light........................................................................................................................................114
			Pilot Cutoff Switch................................................................................................................................114
			Circuit Breaker....................................................................................................................................114
			Fusible Link.......................................................................................................................................115
			Fuse Boxes.........................................................................................................................................115
		Seat Adjustment........................................................................................................................................  0
			7. Storage Compartment.............................................................................................................................118
			8. Left and Right Control Stand Adjustment.........................................................................................................118
		Emergency Glass Breaking Tool..........................................................................................................................127
	Operation..................................................................................................................................................129
		To Handle a New Forest Machine.........................................................................................................................129
			Lubrication and Filters............................................................................................................................130
		Starting and Stopping the Engine.......................................................................................................................130
			Inspection Before Starting Engine..................................................................................................................130
			Operational Checks Before Starting Engine..........................................................................................................131
			Starting Engine With a Booster Cable...............................................................................................................136
			Hydraulic System Warm-up...........................................................................................................................138
			Hydraulic System Warm-up - Cold Weather............................................................................................................139
			Stopping Engine....................................................................................................................................140
			Check and Confirmation After Stopping Engine.......................................................................................................141
		Safety Lever...........................................................................................................................................142
		Travel.................................................................................................................................................143
			Automatic Travel Speed Control.....................................................................................................................144
			Travel Control Lever Operation.....................................................................................................................145
			General Travel Instructions........................................................................................................................146
		Operating Instructions.................................................................................................................................149
			Engine Speed Control...............................................................................................................................149
			Mode Selection.....................................................................................................................................149
			Work Levers (Joysticks) (ISO Pattern)..............................................................................................................151
		Operating Precautions..................................................................................................................................153
			Always Observe These Precautions...................................................................................................................155
			Working in Water...................................................................................................................................156
		Parking Forest Machine.................................................................................................................................157
		Towing Procedure.......................................................................................................................................158
		Lifting Objects........................................................................................................................................159
		Operation Under Unusual Conditions.....................................................................................................................161
			Operation In Extreme Cold..........................................................................................................................161
			Operation in Extreme Heat..........................................................................................................................162
			Operation in Dusty or Sandy Areas..................................................................................................................164
			Operation in Rainy or Humid Conditions.............................................................................................................164
			Operation in Salt Water Areas......................................................................................................................165
			Operation at High Altitudes........................................................................................................................165
	Inspection, Maintenance and Adjustment.....................................................................................................................  0
		Preventive Maintenance.................................................................................................................................  0
			Component Serial Numbers...........................................................................................................................169
			Safety Precautions.................................................................................................................................169
		Preliminary Work Machine Setup for Maintenance.........................................................................................................170
		Table of Recommended Lubricants........................................................................................................................172
			Coolant and Water for Dilution.....................................................................................................................174
		Fluid Capacities.......................................................................................................................................175
		Lubrication and Service Chart..........................................................................................................................175
		Maintenance Intervals..................................................................................................................................178
		10 Hour / Daily Service................................................................................................................................180
			Grease Front Attachment Pins (for first 100 hours).................................................................................................180
			Check Engine Oil Level.............................................................................................................................180
			Check Level of Hydraulic Oil Tank..................................................................................................................181
			Check for Leaks in Hydraulic System................................................................................................................182
			Check Fuel Level...................................................................................................................................183
			Check for Leaks in Fuel System.....................................................................................................................183
			Check Fuel Prefilter and Drain Water As Required...................................................................................................184
			Check Oil Level of Swing Reduction Device..........................................................................................................185
			Clean Dust Net in Front of Oil Cooler and Intercooler..............................................................................................186
			Check Cooling System and Refill As Required........................................................................................................186
			Check Level of Window Washer Liquid................................................................................................................187
			Inspect Cooling Fan Blade..........................................................................................................................187
			Check Air Intake System............................................................................................................................188
			Inspect Seat Belt for Proper Operation.............................................................................................................188
			Inspect Structure for Cracks and Faulty Welds......................................................................................................188
			Check the Operation of All Switches................................................................................................................188
			Check the Operation of Pilot Cutoff Switch.........................................................................................................189
			Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights......................................................190
			Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds....190
			Check Operation of All Controls....................................................................................................................190
		50 Hour / Weekly Service...............................................................................................................................191
			Perform All Daily Service Checks...................................................................................................................191
			Grease Front Attachment Pins.......................................................................................................................191
			Grease Swing Bearing...............................................................................................................................196
			Drain Water and Sediment from Fuel Tank............................................................................................................197
			Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)..................................................................197
			Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)...................................197
		250 Hour / Monthly Service.............................................................................................................................  0
			Check Engine Fan Belt Wear.........................................................................................................................199
			Replace Hydraulic Oil Return Filter (After First 250 Hours)........................................................................................200
			Change Pilot Filter (After First 250 Hours)........................................................................................................200
			Inspect Pins and Bushings of the Front End Attachments for Signs of Wear...........................................................................200
			Check Fluid Levels in Batteries....................................................................................................................200
			Inspect for Any Loose or Missing Nuts and Bolts....................................................................................................200
			Inspect Fuel System Hose Clamps....................................................................................................................200
		500 Hour / 3 Month Service.............................................................................................................................201
			Perform All Daily, 50 and 250 Hour Service Checks..................................................................................................201
			Grease Swing Gear and Pinion.......................................................................................................................201
			Change Engine Oil and Filter.......................................................................................................................202
			Clean Air-Conditioning Outer Filter................................................................................................................203
			Check and Clean Air-Conditioning Inner Filter......................................................................................................204
			Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core............................................................205
			Change of Fuel Prefilter...........................................................................................................................208
			Change Fuel Filter.................................................................................................................................209
			Check Oil Level in Travel Reduction Device (One on Each Side of Unit)..............................................................................210
			Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)...........................................................210
			Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours).........................................................................210
		1,000 Hour / 6 Month Service...........................................................................................................................  0
			Change Swing Reduction Device Oil..................................................................................................................214
			Change Air-Conditioning Outer Filter...............................................................................................................215
			Change Air-Conditioning Inner Filter...............................................................................................................215
			Check Air Conditioner Refrigerant..................................................................................................................216
			Change Fuel Cap Filter.............................................................................................................................217
			Check and Adjust Engine **.........................................................................................................................218
		2,000 Hour / Yearly Service............................................................................................................................219
			Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks......................................................................................219
			Change Oil in Travel Reduction Device (One on Each Side of Unit)...................................................................................219
			Hydraulic Oil Exchange and Suction Strainer Cleaning...............................................................................................223
			Check Alternator and Starter**.....................................................................................................................225
			Check All Rubber Antivibration Shock Mounts........................................................................................................225
			Perform and Record the Results of the Cycle Time Tests.............................................................................................225
			Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage....................................................................225
			Check, Adjust Valve Clearance **...................................................................................................................225
			Check Head Bolt Torques............................................................................................................................225
		4,000 Hour / Biennial Service..........................................................................................................................226
			Major Parts - Periodic Replacement.................................................................................................................226
		12,000 Hour / 6 Year Service...........................................................................................................................227
			Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)..........................................................................227
		Air-Conditioning System................................................................................................................................228
			Check Control Panel................................................................................................................................228
			Check Air Conditioner Hoses........................................................................................................................228
			Check Condenser....................................................................................................................................228
			Check Magnetic Clutch..............................................................................................................................228
			Check Belt Tension.................................................................................................................................228
		Bolt and Nut Inspection................................................................................................................................229
		Electrical System......................................................................................................................................237
			Battery............................................................................................................................................237
			Fuses..............................................................................................................................................239
		Engine Cooling System..................................................................................................................................241
			General............................................................................................................................................241
			Antifreeze Concentration Tables....................................................................................................................243
			Table of Standards for Allowed Tap Water...........................................................................................................243
		Fuel Transfer Pump (Optional)..........................................................................................................................244
		Handling of Accumulator................................................................................................................................247
		Track Tension..........................................................................................................................................248
		Venting and Priming Hydraulic System...................................................................................................................250
			Main System Pump...................................................................................................................................250
			Hydraulic Cylinders................................................................................................................................250
			Swing Motor........................................................................................................................................251
			Travel Motor.......................................................................................................................................251
			General Venting....................................................................................................................................251
		Long Term Storage......................................................................................................................................252
			Before Storage.....................................................................................................................................252
			During Storage.....................................................................................................................................253
			After Storage......................................................................................................................................253
		Maintenance in Special Conditions......................................................................................................................254
	Transportation.............................................................................................................................................255
		Loading and Unloading..................................................................................................................................255
			Warning for Counterweight and Front Attachment Removal.............................................................................................255
		Lifting Machine........................................................................................................................................259
	Troubleshooting............................................................................................................................................261
		Electrical System......................................................................................................................................261
		Engine.................................................................................................................................................262
		Hydraulic System.......................................................................................................................................264
		Swing System...........................................................................................................................................265
		Travel System..........................................................................................................................................265
	Specification..............................................................................................................................................267
		Standard Specification.................................................................................................................................267
		Overall Dimensions.....................................................................................................................................268
		Approximate Weight of Workload Materials...............................................................................................................271
	Index......................................................................................................................................................273

DOOSAN DX225LL EXCAVATOR LOG LOADER FORESTRY MACHINE OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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