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Doosan DX225LL Excavator Log loader Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
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Doosan DX225LL Excavator Log loader Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
Serial Number 5017 and Up
K1045080CE
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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
Serial Number 5017 and Up
K1045080CE
SAFETY DECALS:
- Safety decals are attached to the machine to alert the operator or maintenance person about potential hazards, the consequences of potential injury, and instructions and/or actions required to avoid the hazard.
- The location of the safety decals and the description of the decals are reviewed in the following section. Please become familiarized with all safety decals and their messages. Make sure that all the safety decals are in their correct location and legible.
- Clean or replace the safety decals if they are damaged, missing, or the texts and pictorials are not legible. When you clean the safety decals, use a soft cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety decals because this could loosen the adhesive that secures the decals to the machine.
- Remember, if a safety decal is attached to a part that is replaced, install a new safety decal on the replacement part. This machine uses safety decals with and without text. The type and number of safety decals can vary depending upon geographical regions and machine models.
Safety Decals With Text:
- Safety decals with text consist of a signal word, pictorial and a text message panel. In some cases, a pictorial panel may not be part of the safety decal.
TABLE OF CONTENTS:
Doosan 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................................................................................................................................. 40 Traveling on Slopes................................................................................................................................ 41 Prohibited Operations.............................................................................................................................. 42 Precautions for Operation.......................................................................................................................... 43 Avoid High-voltage Cables.......................................................................................................................... 43 Operate Carefully on Snow, Ice and in Very Cold Temperatures....................................................................................... 44 Operations on Slopes............................................................................................................................... 44 Parking Machine.................................................................................................................................... 45 Never Let Anyone Ride on Attachment................................................................................................................ 45 Maintenance............................................................................................................................................ 0 Proper Tools....................................................................................................................................... 47 Use of Lighting.................................................................................................................................... 47 Fire Prevention and Explosion Prevention........................................................................................................... 47 Burn Prevention.................................................................................................................................... 48 Welding Repairs.................................................................................................................................... 49 Warning for Counterweight and Front Attachment Removal............................................................................................. 50 Precautions for Removal, Installation, and Storage of Attachments.................................................................................. 51 Precautions When Working on Machine................................................................................................................ 51 Lock Inspection Covers............................................................................................................................. 51 Prevention of Crushing and Cutting................................................................................................................. 52 Track Tension Adjustments Require Caution.......................................................................................................... 52 Supports and Blocking for Work Equipment........................................................................................................... 52 Action When Abnormality Is Found During Inspection................................................................................................. 53 Precautions with High-pressure Lines, Tubes and Hoses.............................................................................................. 53 Waste Materials.................................................................................................................................... 54 Hydraulic Cylinders, Pins and Bushings............................................................................................................. 54 Battery................................................................................................................................................ 55 Battery Hazard Prevention.......................................................................................................................... 55 Boost Starting or Charging Engine Batteries........................................................................................................ 56 Towing................................................................................................................................................. 57 Precautions When Towing............................................................................................................................ 57 Shipping and Transportation............................................................................................................................ 58 Obey State and Local Over-the-Road Regulations..................................................................................................... 58 Forest Machine Rated Lift Capacity Tables.............................................................................................................. 59 Operating Controls......................................................................................................................................... 63 Component Locations.................................................................................................................................... 64 Operator's Area........................................................................................................................................ 66 Operational Controls and Panels........................................................................................................................ 68 1. Starter Switch.................................................................................................................................. 70 2. Engine Speed Control Dial....................................................................................................................... 70 3. Auxiliary Mode Switch........................................................................................................................... 71 4. Engine Emergency Stop Switch.................................................................................................................... 71 5. Audio Control Panel............................................................................................................................. 71 6. Travel Speed Selector Switch.................................................................................................................... 73 7. Light Switch.................................................................................................................................... 73 8. Cabin Work Light Switch......................................................................................................................... 73 9. Blank (Empty Switch Socket)..................................................................................................................... 74 12. Heater and Air Conditioner Control Panel....................................................................................................... 74 13. Wiper Switch Panel............................................................................................................................. 74 14. Cigarette Lighter.............................................................................................................................. 75 15. Power Socket for 12 Volt....................................................................................................................... 76 16. Travel Alarm Switch............................................................................................................................ 76 18. Fuel Heater Switch (Optional).................................................................................................................. 76 19. Seat Warmer Switch (Optional).................................................................................................................. 77 20. Horn Button (Left-hand Work Lever)............................................................................................................. 77 21. Rotating Buttons............................................................................................................................... 77 25. Safety Lever................................................................................................................................... 79 26. Photo Sensor................................................................................................................................... 79 Instrument Panel....................................................................................................................................... 0 7. Charge Warning.................................................................................................................................. 84 8. Engine Oil Pressure Warning..................................................................................................................... 84 9. Engine Coolant Temperature Warning.............................................................................................................. 84 Multifunction Gauge and Graphic Information............................................................................................................ 0 Communication Error Warning........................................................................................................................ 87 Engine Speed....................................................................................................................................... 87 Battery Voltage.................................................................................................................................... 87 Mode Selector Buttons.................................................................................................................................. 91 1. Power Mode Selector Button...................................................................................................................... 91 2. Economy Mode Selector Button.................................................................................................................... 91 Operation Selection Display............................................................................................................................ 0 Camera Mode Selector Button........................................................................................................................104 Heater and Air Conditioner Control Panel...............................................................................................................105 Location of Controls and Vents.....................................................................................................................105 Control Panel......................................................................................................................................106 Memory Function....................................................................................................................................110 Additional Operating Instructions..................................................................................................................110 Miscellaneous Electrical Devices.......................................................................................................................112 Cabin Light........................................................................................................................................112 Pilot Cutoff Switch................................................................................................................................112 Circuit Breaker....................................................................................................................................112 Fusible Link.......................................................................................................................................113 Fuse Boxes.........................................................................................................................................113 Seat Adjustment........................................................................................................................................ 0 8. Seat Belt.......................................................................................................................................116 Operation..................................................................................................................................................127 To Handle a New Forest Machine.........................................................................................................................127 Lubrication and Filters............................................................................................................................128 Starting and Stopping the Engine.......................................................................................................................128 Inspection Before Starting Engine..................................................................................................................128 Operational Checks Before Starting Engine..........................................................................................................129 Starting Engine With a Booster Cable...............................................................................................................133 Hydraulic System Warm-up...........................................................................................................................135 Hydraulic System Warm-up - Cold Weather............................................................................................................136 Stopping Engine....................................................................................................................................137 Check and Confirmation After Stopping Engine.......................................................................................................138 Safety Lever...........................................................................................................................................138 Travel.................................................................................................................................................139 Automatic Travel Speed Control.....................................................................................................................140 Travel Control Lever Operation.....................................................................................................................141 General Travel Instructions........................................................................................................................142 Operating Instructions.................................................................................................................................145 Engine Speed Control...............................................................................................................................145 Mode Selection.....................................................................................................................................145 Work Levers (Joysticks) (ISO Pattern)..............................................................................................................147 Operating Precautions..................................................................................................................................149 Always Observe These Precautions...................................................................................................................151 Working in Water...................................................................................................................................152 Parking Forest Machine.................................................................................................................................153 Towing Procedure.......................................................................................................................................154 Lifting Objects........................................................................................................................................155 Operation Under Unusual Conditions.....................................................................................................................157 Operation In Extreme Cold..........................................................................................................................157 Operation in Extreme Heat..........................................................................................................................158 Operation in Dusty or Sandy Areas..................................................................................................................160 Operation in Rainy or Humid Conditions.............................................................................................................160 Operation in Salt Water Areas......................................................................................................................161 Operation at High Altitudes........................................................................................................................161 Inspection, Maintenance and Adjustment..................................................................................................................... 0 Preventive Maintenance................................................................................................................................. 0 Safety Precautions.................................................................................................................................165 Preliminary Work Machine Setup for Maintenance.........................................................................................................166 Table of Recommended Lubricants........................................................................................................................168 Coolant and Water for Dilution.....................................................................................................................170 Fluid Capacities.......................................................................................................................................171 Lubrication and Service Chart..........................................................................................................................171 Maintenance Intervals..................................................................................................................................174 10 Hour / Daily Service................................................................................................................................176 Grease Front Attachment Pins (for first 100 hours).................................................................................................176 Check Engine Oil Level.............................................................................................................................176 Check Level of Hydraulic Oil Tank..................................................................................................................177 Check for Leaks in Hydraulic System................................................................................................................178 Check Fuel Level...................................................................................................................................179 Check for Leaks in Fuel System.....................................................................................................................179 Check Oil Level of Swing Reduction Device..........................................................................................................181 Clean Dust Net in Front of Oil Cooler and Intercooler..............................................................................................182 Check Cooling System and Refill As Required........................................................................................................182 Check Level of Window Washer Liquid................................................................................................................183 Inspect Cooling Fan Blade..........................................................................................................................183 Check Air Intake System............................................................................................................................184 Inspect Seat Belt for Proper Operation.............................................................................................................184 Inspect Structure for Cracks and Faulty Welds......................................................................................................184 Check the Operation of All Switches................................................................................................................184 Check the Operation of Pilot Cutoff Switch.........................................................................................................185 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights......................................................186 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds....186 Check Operation of All Controls....................................................................................................................186 50 Hour / Weekly Service...............................................................................................................................187 Perform All Daily Service Checks...................................................................................................................187 Grease Front Attachment Pins.......................................................................................................................187 Grease Swing Bearing...............................................................................................................................192 Drain Water and Sediment from Fuel Tank............................................................................................................193 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)..................................................................193 Inspect Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers).......................................193 250 Hour / Monthly Service............................................................................................................................. 0 Check Engine Fan Belt Wear.........................................................................................................................195 Replace Hydraulic Oil Return Filter (After First 250 Hours)........................................................................................196 Change Pilot Filter (After First 250 Hours)........................................................................................................196 Inspect Pins and Bushings of Front End Attachments for Signs of Wear...............................................................................196 Check Fluid Levels in Batteries....................................................................................................................196 Inspect for Any Loose or Missing Nuts and Bolts....................................................................................................196 Inspect Fuel System Hose Clamps....................................................................................................................196 500 Hour / 3 Month Service.............................................................................................................................197 Perform All Daily, 50 and 250 Hour Service Checks..................................................................................................197 Grease Swing Gear and Pinion.......................................................................................................................197 Change Engine Oil and Filter.......................................................................................................................198 Clean Air-Conditioning Outer Filter................................................................................................................199 Check and Clean Air-Conditioning Inner Filter......................................................................................................200 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core............................................................201 Change of Fuel Prefilter...........................................................................................................................204 Change Fuel Filter.................................................................................................................................205 Check Oil Level in Travel Reduction Device (One on Each Side of Unit)..............................................................................206 Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)...........................................................206 Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours).........................................................................206 1,000 Hour / 6 Month Service........................................................................................................................... 0 Change Swing Reduction Device Oil..................................................................................................................210 Change Air-Conditioning Outer Filter...............................................................................................................211 Check Air Conditioner Refrigerant..................................................................................................................212 Change Fuel Cap Filter.............................................................................................................................213 Check and Adjust Engine **.........................................................................................................................214 2,000 Hour / Yearly Service............................................................................................................................215 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks......................................................................................215 Change Oil in Travel Reduction Device (One on Each Side of Unit)...................................................................................215 Hydraulic Oil Exchange and Suction Strainer Cleaning...............................................................................................219 Check Alternator and Starter**.....................................................................................................................221 Check All Rubber Antivibration Shock Mounts........................................................................................................221 Perform and Record the Results of Cycle Time Tests.................................................................................................221 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage....................................................................221 Check, Adjust Valve Clearance **...................................................................................................................221 Check Head Bolt Torques............................................................................................................................221 4,000 Hour / Biennial Service..........................................................................................................................222 Major Parts - Periodic Replacement.................................................................................................................222 12,000 Hour / 6 Year Service...........................................................................................................................223 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)..........................................................................223 Air-Conditioning System................................................................................................................................224 Check Control Panel................................................................................................................................224 Check Air Conditioner Hoses........................................................................................................................224 Check Condenser....................................................................................................................................224 Check Magnetic Clutch..............................................................................................................................224 Check Belt Tension.................................................................................................................................224 Bolt and Nut Inspection................................................................................................................................225 Electrical System......................................................................................................................................232 Battery............................................................................................................................................232 Fuses..............................................................................................................................................234 Engine Cooling System..................................................................................................................................236 General............................................................................................................................................236 Antifreeze Concentration Tables....................................................................................................................238 Table of Standards for Allowed Tap Water...........................................................................................................238 Fuel Transfer Pump (Optional)..........................................................................................................................239 Handling of Accumulator................................................................................................................................242 Track Tension..........................................................................................................................................243 Venting and Priming Hydraulic System...................................................................................................................245 Main System Pump...................................................................................................................................245 Hydraulic Cylinders................................................................................................................................245 Swing Motor........................................................................................................................................246 Travel Motor.......................................................................................................................................246 General Venting....................................................................................................................................246 Long Term Storage......................................................................................................................................247 Before Storage.....................................................................................................................................247 During Storage.....................................................................................................................................248 After Storage......................................................................................................................................248 Maintenance in Special Conditions......................................................................................................................249 Transportation.............................................................................................................................................251 Loading and Unloading..................................................................................................................................251 Warning for Counterweight and Front Attachment Removal.............................................................................................251 Lifting Machine........................................................................................................................................255 Troubleshooting............................................................................................................................................257 Electrical System......................................................................................................................................257 Engine.................................................................................................................................................258 Hydraulic System.......................................................................................................................................260 Swing System...........................................................................................................................................261 Travel System..........................................................................................................................................261 Specification..............................................................................................................................................263 Standard Specification.................................................................................................................................263 Overall Dimensions.....................................................................................................................................264 Approximate Weight of Workload Materials...............................................................................................................267 Index......................................................................................................................................................269
DOOSAN DX225LL EXCAVATOR LOG LOADER FORESTRY MACHINE OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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