Doosan DX225LL Excavator Log loader Operation & Maintenance Manual K1045080E-1 – PDF DOWNLOAD

Description

Doosan DX225LL Excavator Log loader Operation & Maintenance Manual K1045080E-1 – PDF DOWNLOAD

DESCRIPTION:

Doosan DX225LL Excavator Log loader Operation & Maintenance Manual K1045080E-1 – PDF DOWNLOAD

GENERAL HAZARD INFORMATION:
Safety Rules

• Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
• Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems.
• These problems will interfere with your sense of judgement in emergencies and may cause accidents. When working with another operator or with a person on work site traffic duty, be sure that all personnel know the nature of the work and understand all hand signals that are to be used. Always observe strictly any other rules related to safety.

Safety Features

• Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as safety lock lever and the seat belt, and use them properly.
• Never remove any safety features. Always keep them in good operating condition. Failure to use safety features according to the instructions in the Operation and Maintenance Manual could result in serious

TABLE OF CONTENTS:

Doosan DX225LL Excavator Log loader Operation & Maintenance Manual K1045080E-1 – PDF DOWNLOAD

Table of Contents...............................................................................................  5
Safety..........................................................................................................  9
	To the Operator of a DOOSAN Forest Machine..................................................................  9
		Learn the Signal Words Used with the Safety Alert Symbol................................................ 11
	Location of Safety Labels................................................................................... 12
		1. Warnings for Operation, Inspection and Maintenance (19000688, 19000092)............................ 13
		2. Warnings for High Voltage (19000689, 19000096)..................................................... 13
		3. Warnings When Opening a Front Window (21903388, 19000093).......................................... 14
		4. Warnings for a Highpressure Cylinder (19000122).................................................... 14
		5. Warnings When Adjusting Track Tension (21903386A, 19000521)........................................ 15
		6. Warnings for Leaving Operator's Seat (19000693, 19000094).......................................... 15
		7. Warnings for Batteries Maintenance (21902533A, 19000100)........................................... 16
		8. Warnings for High Temperature Hydraulic Oil (19000691A, 19000097).................................. 16
		9. Warnings for Hot Coolant (19000692, 19000097)...................................................... 17
		10. Warnings for ECU of Engine (K1012583)............................................................... 17
		11. Warnings for Rotating Parts (19000694, 19000095, 19000557)....................................... 18
		12. Warning Tag  Used When Inspection and Maintenance (19000695A, 19000098A)......................... 18
		13. Warning for a Hot Surface (19000648A).............................................................. 19
		14. Caution for Hood (19000522A)....................................................................... 19
		15. Keep Out of the Swing Area (21903379A, K1008571)................................................... 20
		16. Warnings for Front Attachments (19000652).......................................................... 20
		17. Warning for Intrusion Hazard (21903444)............................................................ 21
		18. Warning for Power Lines (21903450A)................................................................ 21
	Summary of Safety Precautions for Lifting in Digging Mode................................................... 22
	Unauthorized Modifications.................................................................................. 23
	General Hazard Information.................................................................................. 23
		Safety Rules............................................................................................ 23
		Safety Features......................................................................................... 23
		Inside Operator's Compartment........................................................................... 24
		Clothing and Personal Protective Items.................................................................. 25
		Breathing Masks, Ear Protection May Be Required......................................................... 25
		Vibration Level Information............................................................................. 25
		Recommendations for Limiting Vibrations................................................................. 25
		Mounting and Dismounting................................................................................ 26
		Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 27
		Precautions When Handling Fluids at High Temperature.................................................... 27
		Asbestos Dust Hazard Prevention......................................................................... 28
		Injury from Work Equipment.............................................................................. 28
		Fire Extinguisher and First Aid Kit..................................................................... 28
		Protection from Falling or Flying Objects............................................................... 29
		Attachment Precautions.................................................................................. 30
		Accumulator............................................................................................. 30
		Indoor Ventilation...................................................................................... 31
		Emergency Exit.......................................................................................... 31
	Before Starting Engine...................................................................................... 32
		Work Site Precautions................................................................................... 32
		Checks Before Starting Engine........................................................................... 33
		Engine Starting......................................................................................... 33
		Before Operating Machine................................................................................ 34
	Machine Operation........................................................................................... 36
		When Swinging or Changing Direction of Travel........................................................... 36
		Travel Precautions...................................................................................... 37
		Traveling on Slopes..................................................................................... 38
		Prohibited Operations................................................................................... 38
		Precautions for Operation............................................................................... 39
		Avoid High Voltage Cables............................................................................... 40
		Operate Carefully on Snow, Ice and in Very Cold Temperatures............................................ 40
		Operations on Slopes.................................................................................... 41
		Parking Machine......................................................................................... 41
		Never Let Anyone Ride on Attachment..................................................................... 41
	Maintenance................................................................................................. 42
		Warning Tag............................................................................................. 42
		Clean Before Inspection or Maintenance.................................................................. 42
		Proper Tools............................................................................................ 43
		Use of Lighting......................................................................................... 43
		Fire Prevention and Explosion Prevention................................................................ 43
		Burn Prevention......................................................................................... 44
		Welding Repairs......................................................................................... 45
		Warning for Counterweight and Front Attachment Removal.................................................. 46
		Precautions for Removal, Installation, and Storage of Attachments....................................... 47
		Precautions When Working on Machine..................................................................... 47
		Lock Inspection Covers.................................................................................. 47
		Crushing Prevention and Cutting Prevention.............................................................. 47
		Track Tension Adjustments Require Caution............................................................... 48
		Supports and Blocking for Work Equipment................................................................ 48
		Action When Abnormality Is Found During Inspection...................................................... 48
		Precautions with Highpressure Lines, Tubes and Hoses................................................... 49
		Waste Materials......................................................................................... 50
		Hydraulic Cylinders, Pins and Bushings.................................................................. 50
	Battery..................................................................................................... 51
		Battery Hazard Prevention............................................................................... 51
		Boost Starting or Charging Engine Batteries............................................................. 52
	Towing...................................................................................................... 53
		Precautions When Towing................................................................................. 53
	Shipping and Transportation................................................................................. 54
		Obey State and Local OvertheRoad Regulations.......................................................... 54
	Forest Machine Rated Lift Capacity Tables................................................................... 55
Operating Controls.............................................................................................. 59
	Component Locations......................................................................................... 60
	Operator's Area............................................................................................. 62
	Operational Controls and Panels............................................................................. 64
		1. Starter Switch....................................................................................... 66
		2. Engine Speed Control Dial............................................................................ 66
		3. Auxiliary Mode Switch................................................................................ 67
		4. Engine Emergency Stop Switch......................................................................... 67
		5. Audio Control Panel.................................................................................. 67
		6. Travel Speed Selector Switch......................................................................... 69
		7. Light Switch......................................................................................... 69
		8. Cabin Work Light Switch.............................................................................. 69
		9. Blank (Empty Switch Socket).......................................................................... 70
		12. Heater and Air Conditioner Control Panel............................................................ 70
		13. Wiper Switch Panel.................................................................................. 70
		14. Cigarette Lighter................................................................................... 71
		15. Power Socket for 12 Volt............................................................................ 72
		16. Travel Alarm Switch................................................................................. 72
		18. Fuel Heater Switch (Optional)....................................................................... 72
		19. Seat Warmer Switch (Optional)....................................................................... 73
		20. Horn Button (Lefthand Work Lever).................................................................. 73
		21. Rotating Buttons.................................................................................... 73
		22. Booster Button (Righthand Work Lever).............................................................. 74
		23. Grapple Buttons..................................................................................... 74
		24. Instrument Panel.................................................................................... 74
		25. Safety Lever........................................................................................ 75
		26. Photo Sensor........................................................................................ 75
	Instrument Panel............................................................................................ 76
		Functional check........................................................................................ 77
		Password Activated...................................................................................... 77
		1. Fuel Gauge........................................................................................... 78
		2. Engine Coolant Temperature Gauge..................................................................... 78
		3. Hydraulic Oil Temperature Gauge...................................................................... 79
		4. Multifunction Gauge and Graphic Information Area..................................................... 79
		5. Digital Clock........................................................................................ 79
		6. Hour Meter........................................................................................... 80
		7. Charge Warning Light................................................................................. 80
		8. Engine Oil Pressure Warning Light.................................................................... 80
		9. Engine Coolant Temperature Warning Light............................................................. 81
		10. Engine Check Warning Light.......................................................................... 81
		11. Preheating Indicator Light.......................................................................... 82
		12. Work Light Indicator Light.......................................................................... 82
	Multifunction Gauge and Graphic Information................................................................. 83
		Communication Indicator................................................................................. 83
		Communication Error Warning............................................................................. 84
		Engine Speed............................................................................................ 84
		Battery Voltage......................................................................................... 84
		Front Hydraulic Pump Pressure........................................................................... 85
		Rear Hydraulic Pump Pressure............................................................................ 85
		Abnormal State Warning Symbols.......................................................................... 85
	Mode Selector Buttons....................................................................................... 88
		1. Power Mode Selector Button........................................................................... 88
		2. Trenching Mode Selector Button....................................................................... 88
		3. Auto Idle Selector Button............................................................................ 89
		4. Flow Control Button.................................................................................. 89
	Setting Main Menu........................................................................................... 90
		1. Up Arrow Button...................................................................................... 90
		2. Down Arrow Button.................................................................................... 91
		3. Display Selector Button (ESC  Escape)............................................................... 91
		4. SelectionButton..................................................................................... 91
		Display Selection and Escaping.......................................................................... 92
		Main Menu............................................................................................... 92
		Language................................................................................................ 93
		Set Clock............................................................................................... 93
		Filter / Oil Info....................................................................................... 94
		Adjust Display.......................................................................................... 96
		Set Password (Lock and Unlock).......................................................................... 97
	Heater and Air Conditioner Control Panel.................................................................... 99
		Location of Controls and Vents.......................................................................... 99
		Control Panel...........................................................................................100
		Memory Function.........................................................................................105
		Additional Operating Instructions.......................................................................105
	Stereo......................................................................................................106
		Stereo..................................................................................................106
		CD Player (Optional)....................................................................................106
	Miscellaneous Electrical Devices............................................................................107
		Cabin Light.............................................................................................107
		Pilot Cutoff Switch.....................................................................................107
		Circuit Breaker.........................................................................................107
		Fusible Link............................................................................................108
		Fuse Boxes..............................................................................................108
	Seat Adjustment.............................................................................................109
		1. Forward / Backward Adjustment........................................................................109
		2. Seat Tilt and Height Adjustment......................................................................109
		3. Suspension Adjustment................................................................................109
		4. Reclining Position Adjustment........................................................................110
		5. Armrest Angle Adjustment.............................................................................110
		6. Lumbar Support Adjustment............................................................................110
		7. Headrest.............................................................................................110
		8. Seat Belt............................................................................................111
		9. Seat Backpocket.....................................................................................112
		10. Left and Right Control Stand Adjustment.............................................................112
		11. Left and Right Control Stand Height Adjustment......................................................112
		12. Air Suspension Seat (Optional)......................................................................112
		13. Heating the Operator's Seat (Optional)..............................................................113
	Ceiling Cover...............................................................................................113
		Opening the Ceiling Cover...............................................................................113
		Closing the Ceiling Cover...............................................................................113
	Front Windows...............................................................................................114
		Front Upper Window......................................................................................114
		Front Bottom Window.....................................................................................115
	Doors and Access Covers.....................................................................................116
		Door Side Latch.........................................................................................116
		Cabin Riser Access Door.................................................................................116
	Tilt Cab....................................................................................................117
	Cabin Storage Compartments..................................................................................117
	Ashtray.....................................................................................................118
	Sun Visor...................................................................................................118
	Hanger......................................................................................................119
	Cup Holder..................................................................................................119
	Door Window Holder..........................................................................................119
	Emergency Glass Breaking Tool...............................................................................120
	Miscellaneous Access Covers and Doors.......................................................................120
		Side Door...............................................................................................120
		Battery Box Door........................................................................................120
		Engine Cover............................................................................................121
Operation.......................................................................................................123
	To Handle a New Forest Machine..............................................................................123
		Lubrication and Filters.................................................................................124
	Starting and Stopping the Engine............................................................................124
		Inspection Before Starting Engine.......................................................................124
		Operational Checks Before Starting Engine...............................................................125
		Engine Start............................................................................................126
		Cold Weather Starting...................................................................................128
		Starting Engine With a Booster Cable....................................................................129
		Hydraulic System Warmup................................................................................131
		Hydraulic System Warmup – Cold Weather.................................................................132
		Engine Shut Down........................................................................................133
		Check and Confirmation After Stopping Engine............................................................134
	Safety Lever................................................................................................135
	Travel......................................................................................................136
		Automatic Travel Speed Control..........................................................................136
		Travel Control Lever Operation..........................................................................138
		General Travel Instructions.............................................................................139
	Operating Instructions......................................................................................142
		Engine Speed Control....................................................................................142
		Mode Selection..........................................................................................142
		Work Levers (Joysticks) (ISO Style).....................................................................144
	Operating Precautions.......................................................................................146
		Always Observe These Precautions........................................................................148
		Working in Water........................................................................................149
	Parking Forest Machine......................................................................................150
	Towing Procedure............................................................................................151
	Operating Techniques........................................................................................152
		Lifting.................................................................................................152
	Operation Under Unusual Conditions..........................................................................154
		Operation In Extreme Cold...............................................................................154
		Operation in Extreme Heat...............................................................................155
		Operation in Dusty or Sandy Areas.......................................................................156
		Operation in Rainy or Humid Conditions..................................................................156
		Operation in Salt Water Areas...........................................................................157
		Operation at High Altitudes.............................................................................157
Inspection, Maintenance and Adjustment..........................................................................159
	Preventive Maintenance......................................................................................159
		Product Identification Number (P. I. N.) Location.......................................................160
		Component Serial Numbers................................................................................160
		Safety Precautions......................................................................................161
	Preliminary Work Machine Setup for Maintenance..............................................................162
	Table of Recommended Lubricants.............................................................................164
	Fluid Capacities............................................................................................166
	Lubrication and Service Chart...............................................................................166
	Maintenance Intervals.......................................................................................170
	10 Hour / Daily Service.....................................................................................172
		Grease Front Attachment Pins (for first 100 hours)......................................................172
		Check Engine Oil Level..................................................................................172
		Check Level of Hydraulic Oil Tank.......................................................................173
		Check for Leaks in Hydraulic System.....................................................................174
		Check Fuel Level........................................................................................174
		Check for Leaks in Fuel System..........................................................................175
		Check Fuel Prefilter and Drain Water As Required........................................................175
		Check Oil Level of Swing Reduction Device...............................................................176
		Clean Dust Net in Front of Oil Cooler and Intercooler...................................................177
		Check Cooling System and Refill As Required.............................................................178
		Check Level of Window Washer Liquid.....................................................................178
		Inspect Cooling Fan Blade...............................................................................179
		Check Air Intake System.................................................................................179
		Inspect Seat Belt for Proper Operation..................................................................179
		Inspect the Structure for Cracks and Faulty Welds.......................................................180
		Check the Operation of All Switches.....................................................................180
		Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......180
		Start Engine, Check Starting Ability, and Observe Exhaust Color at Startup and at Normal Operati.......180
		Check Operation of All Controls.........................................................................181
	50 Hour / Weekly Service....................................................................................182
		Perform All Daily Service Checks........................................................................182
		Grease Front Attachment Pins............................................................................182
		Grease Swing Bearing....................................................................................188
		Drain Water and Sediment from Fuel Tank.................................................................188
		Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours).......................188
		Change Engine Oil and Filter (After First 50 Hours).....................................................188
		Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, R.......188
	250 Hour / Monthly Service..................................................................................189
		Perform All Daily and 50 Hour Service Checks............................................................189
		Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours)..............................189
		Check Engine Fan Belt Tension...........................................................................189
		Check Engine Fan Belt Wear..............................................................................190
		Check Oil Level in Travel Reduction Device (One on Each Side of Unit)...................................191
		Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 250 Hours)................191
		Replace Hydraulic Oil Return Filter (After First 250 Hours).............................................191
		Change Pilot Filter (After First 250 Hours).............................................................191
		Inspect Pins and Bushings of the Front End Attachments for Signs of Wear................................192
		Check Fluid Levels in Batteries and Battery Charge Levels...............................................192
		Inspect for Any Loose or Missing Nuts and Bolts.........................................................192
		Inspect Fuel System Hose Clamps.........................................................................192
	500 Hour / 3 Month Service..................................................................................193
		Perform All Daily, 50 and 250 Hour Service Checks.......................................................193
		Grease Swing Gear and Pinion............................................................................193
		Change Engine Oil and Filter............................................................................194
		Clean AirConditioning Outer Filter.....................................................................195
		Check and Clean AirConditioning Inner Filter...........................................................196
		Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core.................197
		Clean Outer Filter of Air Cleaner.......................................................................198
		Change of Fuel Prefilter................................................................................200
		Change Fuel Filter......................................................................................201
	1,000 Hour / 6 Month Service................................................................................202
		Perform All Daily, 50, 250 and 500 Hour Service Checks..................................................202
		Grease Swing Reduction Device...........................................................................202
		Change Pilot Filter.....................................................................................204
		Change Oil in Travel Reduction Device (One on Each Side of Unit)........................................205
		Change Air Breather Filter..............................................................................205
		Change AirConditioning Outer Filter....................................................................206
		Check Air Conditioner Refrigerant.......................................................................207
		Check and Adjust Engine **..............................................................................207
	2,000 Hour / Yearly Service.................................................................................208
		Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks...........................................208
		Change Swing Reduction Device Oil.......................................................................208
		Replace Outer and Inner Air Cleaner Elements............................................................209
		Change Radiator Coolant.................................................................................210
		Hydraulic Oil Exchange and Suction Strainer Cleaning....................................................211
		Check Alternator and Starter**..........................................................................213
		Check All Rubber Antivibration Shock Mounts.............................................................213
		Perform and Record the Results of the Cycle Time Tests..................................................213
		Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.........................213
		Check, Adjust Valve Clearance **........................................................................213
		Check Head Bolt Torques.................................................................................213
	4,000 Hour / Biennial Service...............................................................................214
		Major Parts  Periodic Replacement......................................................................214
	12,000 Hour / Six Year Service..............................................................................215
		Hose Inservice Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................215
	AirConditioning System.....................................................................................216
		Check Control Panel.....................................................................................216
		Check Air Conditioner Hoses.............................................................................216
		Check Condenser.........................................................................................216
		Check Magnetic Clutch...................................................................................216
		Check Belt Tension......................................................................................216
	Bolt and Nut Inspection.....................................................................................217
	Electrical System...........................................................................................224
		Battery.................................................................................................224
		Fuses...................................................................................................225
	Engine Cooling System.......................................................................................228
		General.................................................................................................228
		Antifreeze Concentration Tables.........................................................................229
	Fuel Transfer Pump (Optional)...............................................................................230
	Handling of Accumulator.....................................................................................233
	Track Tension...............................................................................................234
	Venting and Priming Hydraulic System........................................................................236
		Main System Pump........................................................................................236
		Hydraulic Cylinders.....................................................................................236
		Swing Motor.............................................................................................237
		Travel Motor............................................................................................237
		General Venting.........................................................................................237
	Long Term Storage...........................................................................................238
	Maintenance in Special Conditions...........................................................................239
Transportation..................................................................................................241
	Loading and Unloading.......................................................................................241
		Warning for Counterweight and Front Attachment Removal..................................................241
	Lifting With Sling..........................................................................................245
Troubleshooting.................................................................................................247
	Electrical System...........................................................................................247
	Engine......................................................................................................248
	Hydraulic System............................................................................................250
	Swing System................................................................................................251
	Travel System...............................................................................................251
Specification...................................................................................................253
	Standard Specification......................................................................................253
	Overall Dimensions..........................................................................................254
	Working Range...............................................................................................256
	Approximate Weight of Workload Materials....................................................................257
Index...........................................................................................................259

DOOSAN DX225LL EXCAVATOR LOG LOADER OPERATION & MAINTENANCE MANUAL K1045080E-1 – PDF DOWNLOAD:

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