DOOSAN DX225MH 3 OPERATION &MAINTENANCE MANUAL 950106-01406NA – PDF DOWNLOAD

Description

DOOSAN DX225MH 3 OPERATION &MAINTENANCE MANUAL 950106-01406NA – PDF DOWNLOAD

DESCRIPTION:

DOOSAN DX225MH 3 OPERATION &MAINTENANCE MANUAL 950106-01406NA – PDF DOWNLOAD

FOREWORD

This Operation and Maintenance Manual was written to give owner or operator instructions on safe operation and maintenance of DOOSAN equipment. READ AND UNDERSTAND THIS OPERATION AND MAINTENANCE MANUAL BEFORE OPERATING YOUR DOOSAN EQUIPMENT. Keep this manual in the cabin so it is always available. If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment. Any modification made without written authorization or approval from DOOSAN can create a safety hazard. Always replace parts with genuine DOOSAN parts or DOOSAN authorized replacement parts.

Intended Use

The machine is intended to be used under normal conditions for applications described in this manual. If it is used for other purposes, or in potentially hazardous environments, special precautions must be followed and the machine must be equipped for such use. Examples include, but are not limited to, are: falling object guards, work lights, etc. Do not engage in prohibited uses as described in this manual. Contact your DOOSAN distributor for further information

Engine and Emission Control System Maintenance

Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating. This includes proper inspection and maintenance of the machine’s emission control system. This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and/or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance. The required maintenance procedures are outlined in this Operation and Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system.

TABLE OF CONTENTS:

DOOSAN DX225MH 3 OPERATION &MAINTENANCE MANUAL 950106-01406NA – PDF DOWNLOAD

Foreword....................................................................................................................................................  5
	Intended Use............................................................................................................................................  5
	Engine and Emission Control System Maintenance..........................................................................................................  5
	Safety Messages.........................................................................................................................................  8
	AEM Safety Manual (North America Only)..................................................................................................................  9
	Federal Emission Control Systems........................................................................................................................ 10
		Limited Warranty for Non-road Engines (CI).......................................................................................................... 10
		Owner’s Warranty Rights and Obligations............................................................................................................. 10
		Manufacturer’s Warranty Coverage.................................................................................................................... 11
		Owner’s Warranty Responsibilities................................................................................................................... 11
Safety...................................................................................................................................................... 17
	Safety Decals........................................................................................................................................... 18
		Safety Decals With Text............................................................................................................................. 18
		Safety Decals Without Text (No-Text)................................................................................................................ 19
		Information and Location for Safety Decals.......................................................................................................... 20
			Tilting Riser................................................................................................................................... 20
		Information and Location for Safety Decals (Continued).............................................................................................. 21
			Tilting Riser (Continued)....................................................................................................................... 21
		Information and Location for Safety Decals (Continued).............................................................................................. 22
			Elevating Cab................................................................................................................................... 22
		Information and Location for Safety Decals (Continued).............................................................................................. 23
			Elevating Cab (Continued)....................................................................................................................... 23
		Information and Location of Additional Decals....................................................................................................... 36
			Tilting Riser................................................................................................................................... 36
		Information and Location of Additional Decals (Continued)........................................................................................... 37
			Tilting Riser (Continued)....................................................................................................................... 37
		Information and Location of Additional Decals (Continued)........................................................................................... 38
			Elevating Cab................................................................................................................................... 38
		Information and Location of Additional Decals (Continued)........................................................................................... 39
			Elevating Cab (Continued)....................................................................................................................... 39
		Information and Location of Additional Decals (Continued)...........................................................................................  0
			4. Emergency Cab Lowering (7238715) (Elevating Cab Only)........................................................................................ 41
			5. Emergency Cab Lowering ( 7238716) (Elevating Cab Only)....................................................................................... 41
			6. Emergency Cab Lowering (7238717) (Elevating Cab Only)........................................................................................ 41
	General................................................................................................................................................. 43
		Safe Operation is Operator's Responsibility......................................................................................................... 43
		Know Your Machine................................................................................................................................... 43
		Proper Work Tools and Attachments................................................................................................................... 44
		Pressurized Fluids.................................................................................................................................. 44
		Flying or Falling Objects........................................................................................................................... 45
		Personal Protective Equipment (PPE)................................................................................................................. 46
		Correction of Machine Problems...................................................................................................................... 46
		Crushing and Cutting................................................................................................................................ 46
		Hot Coolant and Oils - Burn Prevention.............................................................................................................. 47
		Fire and Explosion Prevention....................................................................................................................... 48
			Maintenance..................................................................................................................................... 48
			Operation....................................................................................................................................... 48
			Electrical...................................................................................................................................... 49
			Hydraulic System................................................................................................................................ 49
			Fueling......................................................................................................................................... 50
			Never Use Ether Starting Aids................................................................................................................... 50
			Welding and Grinding............................................................................................................................ 50
			If a Fire Occurs................................................................................................................................ 51
		Fire Extinguisher and First-Aid Kit (Emergency Medical Kit)......................................................................................... 51
		Electrical System and Electrical Shock.............................................................................................................. 52
			Protecting Cabin from Flying or Falling Objects (Optional)...................................................................................... 53
			Emergency Exit from Operator's Station.......................................................................................................... 54
			Tilting Riser Egress Ladder..................................................................................................................... 54
			Lowering Elevating Cab.......................................................................................................................... 55
	Transportation.......................................................................................................................................... 56
		Obey State and Local Over-the-Road Regulations...................................................................................................... 56
		Loading and Unloading............................................................................................................................... 56
		Transporting Machine................................................................................................................................ 57
	Operation............................................................................................................................................... 58
		Before Engine Starting.............................................................................................................................. 58
			Machine Condition............................................................................................................................... 58
		Work Site........................................................................................................................................... 59
		Mounting/Dismounting................................................................................................................................ 60
			Elevating Cab (If Equipped)..................................................................................................................... 60
			Tilting Riser (If Equipped)..................................................................................................................... 61
		Cleaning............................................................................................................................................ 62
		Operator Station.................................................................................................................................... 62
		Seat Belt........................................................................................................................................... 63
		Visibility Information.............................................................................................................................. 64
			Work Site Rules................................................................................................................................. 64
		Boost Starting or Charging Engine Batteries......................................................................................................... 65
		Swinging or Traveling............................................................................................................................... 67
		Lifting............................................................................................................................................. 69
		Towing.............................................................................................................................................. 70
		Attachment.......................................................................................................................................... 71
		Equipment Lowering with Engine Stopped.............................................................................................................. 71
		Lowering Elevating Cab with Engine Stopped.......................................................................................................... 72
		Engine Stop......................................................................................................................................... 72
		Parking Machine..................................................................................................................................... 73
		Preservation/Storing Machine........................................................................................................................ 74
			Check After Long-term Parking................................................................................................................... 75
	Maintenance............................................................................................................................................. 76
		Cleaning............................................................................................................................................ 80
		Proper Tools and Clothing........................................................................................................................... 80
		Disassembling Precautions........................................................................................................................... 80
		Use of Lighting..................................................................................................................................... 81
		Fire and Explosion Prevention....................................................................................................................... 81
		Burn Prevention..................................................................................................................................... 82
		Rubber That Contains Fluorides...................................................................................................................... 83
		Rubber and Plastics................................................................................................................................. 84
			Waste Hazardous to the Environment.............................................................................................................. 84
			Check List After Fire........................................................................................................................... 84
		Welding Repairs..................................................................................................................................... 85
			Preparation for Electrical Welding On Body Structure............................................................................................ 86
		Warning for Counterweight and Front Attachment Removal.............................................................................................. 86
		Lock Inspection Covers.............................................................................................................................. 87
		Working on Machine.................................................................................................................................. 87
		Accumulator......................................................................................................................................... 88
		Compressed Air...................................................................................................................................... 88
		Track Tension Adjustments........................................................................................................................... 89
		Supports and Blocking for Work Equipment............................................................................................................ 89
		High-pressure Lines, Tubes and Hoses................................................................................................................ 90
		Battery............................................................................................................................................. 91
			Battery Hazard Prevention....................................................................................................................... 91
	Environment and Circumstances........................................................................................................................... 93
		Work Site Areas Requiring Extra Caution............................................................................................................. 93
			Drop-off or Edge................................................................................................................................ 93
			Poor Visibility................................................................................................................................. 93
			Loose or Soft Ground............................................................................................................................ 94
		High-voltage Cables................................................................................................................................. 94
		Working in Water.................................................................................................................................... 95
		Working in Contaminated Environment................................................................................................................. 95
		Operation in Extreme Conditions..................................................................................................................... 96
			Operation In Extreme Cold....................................................................................................................... 96
			Operation in Extreme Heat....................................................................................................................... 97
			Operation In Dusty and Sandy Areas.............................................................................................................. 98
			Operation in Rainy or Humid Conditions.......................................................................................................... 98
			Operation in Saltwater Areas.................................................................................................................... 99
			Operation at High Altitudes..................................................................................................................... 99
			Operation During Electrical Storms.............................................................................................................. 99
		Exhaust Ventilation.................................................................................................................................100
			Ventilation for Enclosed Area...................................................................................................................100
		Asbestos Information................................................................................................................................100
		Silica Dust Information.............................................................................................................................101
		Disposal of Hazardous Materials.....................................................................................................................101
		Sound...............................................................................................................................................102
		Vibration...........................................................................................................................................102
Operating Controls..........................................................................................................................................103
	Component Locations.....................................................................................................................................104
		Tilting Riser.......................................................................................................................................106
		Elevating Cab.......................................................................................................................................107
	Operator's Area.........................................................................................................................................108
	Operational Controls and Panels.........................................................................................................................110
		1. Starter Switch...................................................................................................................................112
		2. Heater and Air Conditioner Control Panel.........................................................................................................112
		3. Power Socket for 12 Volt.........................................................................................................................113
		4. Cigarette Lighter................................................................................................................................113
		5. Engine Emergency Stop Switch.....................................................................................................................113
		6. Engine Speed Control Dial........................................................................................................................114
		7. Travel Speed Selector Switch.....................................................................................................................114
		8. Light Switch.....................................................................................................................................114
		9. Elevating Cab Switch (Optional)..................................................................................................................115
		10. Cabin Work Light Switch (Optional)..............................................................................................................115
		11. Audio Control Panel.............................................................................................................................115
		12. Wiper Control Panel.............................................................................................................................117
		13. Generator Switch (Optional).....................................................................................................................118
		14. Air Compressor Switch (Optional)................................................................................................................119
		15. Warning Light Switch (Optional).................................................................................................................119
		16. Lower Wiper Switch (Optional)...................................................................................................................119
		17. Travel/Swing Alarm Switch (Optional)............................................................................................................120
		18. Fuel Heater Switch (Optional)...................................................................................................................120
		19. Overload Warning Switch (N/A)...................................................................................................................121
		20. Power Socket for 12 Volt (Optional).............................................................................................................121
		21. Horn Button (Left-hand Work Lever)..............................................................................................................121
		22. Booster Button..................................................................................................................................122
		23. Rotating Switch.................................................................................................................................122
		24. Shear Switch (Not Applicable)...................................................................................................................122
		25. Display Monitor.................................................................................................................................123
		26. Photo Sensor....................................................................................................................................123
		27. Safety Lever....................................................................................................................................123
		28. Auxiliary Mode Switch...........................................................................................................................124
		29. Hour Meter......................................................................................................................................124
		30. Diesel Particulate Filter (DPF) Switch..........................................................................................................125
		31. One Touch Deceleration Button...................................................................................................................125
		32. Intelligent Floating Boom Temporary Reset Button (N/A)..........................................................................................126
		33. Jog Switch Control Panel........................................................................................................................126
		34. Jack Assembly...................................................................................................................................128
		35. Micro Phone (Optional)..........................................................................................................................128
		36. Elevating Cab Lowering Valve (Elevating Cab Only)...............................................................................................129
		37. Not Used........................................................................................................................................129
		38. Magnet Control (If Equipped)....................................................................................................................129
	Tilting Riser...........................................................................................................................................130
		Hydraulic Pump for Tilting Cylinder.................................................................................................................130
		Raising Riser/Cab to Operating Position.............................................................................................................131
		Lowering Riser/Cab to Transport Position............................................................................................................135
	Elevating Cab...........................................................................................................................................139
		Raising.............................................................................................................................................139
		Lowering............................................................................................................................................139
	Display Monitor.........................................................................................................................................140
		Functional Check....................................................................................................................................140
		Password Activated..................................................................................................................................141
		1. Fuel Gauge.......................................................................................................................................141
		2. Engine Coolant Temperature Gauge.................................................................................................................141
		3. Hydraulic Oil Temperature Gauge..................................................................................................................142
		4. Multifunction Gauge and Graphic Information Area.................................................................................................142
		5. ECO Gauge........................................................................................................................................144
		6. Digital Clock....................................................................................................................................144
		7. Display Warning Symbols..........................................................................................................................145
		9. Function Buttons.................................................................................................................................151
		10. Mode Selector Buttons...........................................................................................................................153
		11. Selector Function Display.......................................................................................................................154
		12. Jog Switch......................................................................................................................................154
		13. Camera Mode Selector/ESC Button.................................................................................................................154
		14. Multimedia Selector Button......................................................................................................................155
		Warning Pop-up Window...............................................................................................................................155
	User Menu...............................................................................................................................................  0
		Switch Operation Indication.........................................................................................................................186
	Heater and Air Conditioner Control Panel................................................................................................................189
		Location of Controls and Vents......................................................................................................................189
		Control Panel.......................................................................................................................................190
		Memory Function.....................................................................................................................................194
		Additional Operating Instructions...................................................................................................................194
	Miscellaneous Electrical Devices........................................................................................................................196
		Cabin Light.........................................................................................................................................196
		Pilot Cutoff Switch.................................................................................................................................196
		Circuit Breaker.....................................................................................................................................196
		Fusible Link........................................................................................................................................197
		Fuse Boxes..........................................................................................................................................197
	Seat Adjustment.........................................................................................................................................  0
		7. Storage Compartment..............................................................................................................................200
		8. Left and Right Control Stand Adjustment..........................................................................................................200
	Cabin Riser Access Door.................................................................................................................................206
	Cabin Storage Compartments..............................................................................................................................206
	Cup Holder..............................................................................................................................................209
	Emergency Exit Glass Breaking Tool......................................................................................................................209
	Miscellaneous Access Covers and Doors...................................................................................................................210
		Side Door...........................................................................................................................................210
		Battery Box Door....................................................................................................................................210
		Engine Cover........................................................................................................................................210
	Air Gun and Compressor (Optional).......................................................................................................................211
		Air Gun (Optional)..................................................................................................................................211
		How to Use Air Compressor...........................................................................................................................211
Operation...................................................................................................................................................215
	To Operate a New Material Handler.......................................................................................................................215
		Lubrication and Filters.............................................................................................................................216
	Starting and Stopping Engine............................................................................................................................216
		Inspection Before Starting Engine...................................................................................................................216
			Walk Around Checks..............................................................................................................................216
			Checks Before Starting Engine...................................................................................................................217
		Operational Checks Before Starting Engine...........................................................................................................218
		Engine Start........................................................................................................................................219
		Cold Weather Starting...............................................................................................................................221
		Engine Coolant Heater (Optional)....................................................................................................................223
		Starting Engine With a Booster Cable................................................................................................................225
			Connecting Booster Batteries....................................................................................................................225
			Disconnecting Booster Batteries.................................................................................................................226
		Hydraulic System Warm-up............................................................................................................................226
		Hydraulic System Warm-up - Cold Weather.............................................................................................................227
		Stopping Engine.....................................................................................................................................229
		Checks and Maintenance After Stopping Engine........................................................................................................230
	Safety Lever............................................................................................................................................230
	Travel..................................................................................................................................................231
		Automatic Travel Speed Control......................................................................................................................231
		Travel Control Lever Operation......................................................................................................................232
		General Travel Instructions.........................................................................................................................233
		Straight Travel Pedal (Optional)....................................................................................................................235
			Operating.......................................................................................................................................236
			Locking Pedal...................................................................................................................................236
	Operating Instructions..................................................................................................................................237
		Engine Speed Control................................................................................................................................237
		Engine Exhaust Emission Control System..............................................................................................................237
			Regeneration of Diesel Particulate Filter (DPF).................................................................................................238
			Diesel Particulate Filter (DPF) Regeneration Light and Switch...................................................................................238
			Passive Regeneration............................................................................................................................241
			Active Regeneration.............................................................................................................................241
			Manual (Forced) Regeneration....................................................................................................................242
			DPF Cleaning (Removing Ash in DPF)..............................................................................................................244
			Removal and Installation of the DPF Assembly....................................................................................................245
		Mode Selection......................................................................................................................................246
			Power Mode......................................................................................................................................246
			Work Mode.......................................................................................................................................247
			Auto Idle Mode..................................................................................................................................247
			Boost Mode......................................................................................................................................248
		Work Levers (Joysticks) (ISO Pattern)...............................................................................................................249
			Left-hand Work Lever (Joystick) (Figure 58 and Figure 59).......................................................................................249
			Right-hand Work Lever (Joystick) (Figure 58 and Figure 61)......................................................................................249
		Work Levers (Joysticks) (BHL Pattern)...............................................................................................................251
			Left-hand Work Lever (Joystick) (Figure 62 and Figure 64).......................................................................................251
			Right-hand Work Lever (Joystick) (Figure 62 and Figure 65)......................................................................................251
	Operating Precautions...................................................................................................................................252
		Working in Water....................................................................................................................................257
	Parking Material Handler................................................................................................................................258
	Towing Procedure........................................................................................................................................259
	Attachments.............................................................................................................................................260
		Rotating Operation..................................................................................................................................260
		Grapple (If Equipped)...............................................................................................................................260
			Installation and Removal........................................................................................................................260
		Magnet (If Equipped)................................................................................................................................261
			Switching From Grapple to Magnet................................................................................................................261
			Switching From Magnet to Grapple................................................................................................................263
	Lifting Objects.........................................................................................................................................265
		Lifting Unknown Weight..............................................................................................................................266
		Lifting Known Weight................................................................................................................................266
		Pick and Carry......................................................................................................................................266
	Operation Under Abnormal Conditions.....................................................................................................................267
		Operation in Extreme Cold...........................................................................................................................267
		Operation in Extreme Heat...........................................................................................................................268
		Operation in Dusty and Sandy Areas..................................................................................................................269
		Operation in Rainy or Humid Conditions..............................................................................................................270
		Operation in Saltwater Areas........................................................................................................................270
		Operation During Electrical Storms..................................................................................................................270
		Operation at High Altitudes.........................................................................................................................271
		Equipment Lowering with Engine Stopped..............................................................................................................271
			Machine With a Boom Lowering Control Valve......................................................................................................272
	Long Term Storage.......................................................................................................................................273
		Before Storage......................................................................................................................................273
		During Storage......................................................................................................................................274
		After Storage.......................................................................................................................................274
Inspection, Maintenance and Adjustment......................................................................................................................275
	Maintenance Information.................................................................................................................................275
		Operational Hour Meter Reading......................................................................................................................275
		DOOSAN Genuine Replacement Parts....................................................................................................................275
		DOOSAN Genuine Lubricants...........................................................................................................................275
		Windshield Washer Fluid.............................................................................................................................275
		Fresh and Clean Lubricants..........................................................................................................................275
		Check Drained Oil and Used Filter...................................................................................................................275
		Fuel Strainer.......................................................................................................................................275
		Welding Instructions................................................................................................................................276
		Do Not Drop Things Inside Machine...................................................................................................................276
		Dusty Work Site.....................................................................................................................................276
		Avoid Mixing Lubricants.............................................................................................................................276
		Locking Inspection Covers...........................................................................................................................276
		Hydraulic System - Air Bleeding.....................................................................................................................277
		Hydraulic Hose Installation.........................................................................................................................277
		Checks After Inspection and Maintenance Works.......................................................................................................277
		Safety Precautions..................................................................................................................................278
	Machine Setup Position for Maintenance..................................................................................................................279
	Maintenance Handling Access.............................................................................................................................281
		Entering/Leaving/Climbing On Machine................................................................................................................281
			Elevating Cab (If Equipped).....................................................................................................................281
			Titling Riser (If Equipped).....................................................................................................................282
	Handling Oil, Fuel, Coolant.............................................................................................................................283
		Oil.................................................................................................................................................283
		Fuel................................................................................................................................................283
		Engine Oil..........................................................................................................................................285
		Grease..............................................................................................................................................286
		Coolant and Water for Dilution......................................................................................................................286
		Filters.............................................................................................................................................287
	Electrical System Maintenance...........................................................................................................................288
	Recommend Fuel, Coolant, and Lubricant..................................................................................................................289
		Lubrication.........................................................................................................................................289
		Symbols for "Lubrication and Service Chart".........................................................................................................290
			Lubrication and Service Chart...................................................................................................................291
			Lubrication and Service Chart (Continued).......................................................................................................292
	Fluid Capacities........................................................................................................................................294
	Table of Recommended Lubricants.........................................................................................................................295
	Maintenance Intervals...................................................................................................................................297
	10 Hour / Daily Service.................................................................................................................................300
		Grease Boom, Arm and Front Attachment Pins (for first 100 hours)....................................................................................300
		Grease Elevating Cab Linkage Pins (If equipped) (for first 100 hours)...............................................................................300
		Check Engine Oil Level..............................................................................................................................300
		Check Level of Hydraulic Oil Tank...................................................................................................................301
		Check for Leaks in Hydraulic System.................................................................................................................302
		Check Fuel Level....................................................................................................................................303
		Check for Leaks in Fuel System......................................................................................................................304
		Check Fuel Prefilter and Drain Water As Required....................................................................................................304
		Check Oil Level of Swing Reduction Device...........................................................................................................305
		Clean Dust Net in Front of Oil Cooler and Intercooler...............................................................................................306
		Check Cooling System and Refill As Required.........................................................................................................306
		Check Level of Window Washer Liquid.................................................................................................................307
		Inspect Cooling Fan Blade...........................................................................................................................307
		Check Air Intake System and Emission Control System Components......................................................................................308
		Inspect Seat Belt for Proper Operation..............................................................................................................308
		Inspect Rear View Camera for Proper Operation (If Equipped).........................................................................................308
		Inspect Mirrors for Damage and Adjust and Clean as Required.........................................................................................309
		Inspect Structure for Cracks and Faulty Welds.......................................................................................................309
		Check Operation of All Switches and Travel Alarm (If Equipped)......................................................................................309
		Check the Operation of Pilot Cutoff Switch..........................................................................................................309
			Inspection and Maintenance of the Pilot Cutoff Switch...........................................................................................309
		Check Operation of All Exterior Lights, Horn and Control Console Indicator and Display Monitor......................................................310
		Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds.....310
		Check Operation of All Controls and Linkages........................................................................................................311
	50 Hour / Weekly Service................................................................................................................................312
		Perform All Daily Service Checks....................................................................................................................312
		Grease Boom and Attachment Joint Pin................................................................................................................312
		Grease Elevating Cab Linkage Pins...................................................................................................................314
		Grease Swing Bearing................................................................................................................................316
		Drain Water and Sediment from Fuel Tank.............................................................................................................316
		Check Air Compressor and Drain Water as Required....................................................................................................316
		Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)...................................................................317
		Change Engine Oil and Filter (After First 50 Hours).................................................................................................317
		Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)....................................317
	250 Hour / Monthly Service..............................................................................................................................318
		Perform All Daily and 50 Hour Service Checks........................................................................................................318
		Hydraulic Pump for Tilt Cylinder....................................................................................................................318
		Check Engine Fan and Alternator Belts Wear..........................................................................................................320
		Replace Hydraulic Oil Return Filter (After First 250 Hours).........................................................................................321
		Change Pilot Filter (After First 250 Hours).........................................................................................................321
		Inspect Pins and Bushings of the Front End Attachments for Signs of Wear............................................................................321
		Check Fluid Levels in Batteries and Battery Charge Levels...........................................................................................321
		Inspect for Any Loose or Missing Nuts and Bolts.....................................................................................................321
		Inspect Fuel System Hose Clamps.....................................................................................................................321
	500 Hour / 3 Month Service..............................................................................................................................322
		Perform All Daily, 50 and 250 Hour Service Checks...................................................................................................322
		Grease Swing Gear and Pinion........................................................................................................................322
		Change Engine Oil and Filter........................................................................................................................323
		Clean Air-conditioning Outer Filter.................................................................................................................324
		Check and Clean Air-conditioning Inner Filter.......................................................................................................325
		Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Cores............................................................326
		Clean Outer Filter of Air Cleaner...................................................................................................................327
		Change of Fuel Prefilter............................................................................................................................329
		Change Fuel Filter..................................................................................................................................330
			Fuel System Priming.............................................................................................................................330
		Check Oil Level in Travel Reduction Device (One on Each Side of Unit)...............................................................................332
		Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)............................................................332
		Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours)..........................................................................332
	1,000 Hour / 6 Month Service............................................................................................................................333
		Perform All Daily, 50, 250 and 500 Hour Service Checks..............................................................................................333
		Grease Swing Reduction Device.......................................................................................................................333
		Change Hydraulic Oil Tank Breather Filter...........................................................................................................333
		Change Pilot Filter.................................................................................................................................335
		Change Oil in Travel Reduction Device (One on Each Side of Unit)....................................................................................336
		Change Swing Reduction Device Oil...................................................................................................................337
		Change Air-conditioning Outer Filter................................................................................................................338
		Change Air-conditioning Inner Filter................................................................................................................338
		Check Air Conditioner Refrigerant...................................................................................................................339
		Change Fuel Cap Filter..............................................................................................................................340
		Check and Adjust Engine**...........................................................................................................................341
	2,000 Hour / Yearly Service.............................................................................................................................  0
		Change Radiator Coolant.............................................................................................................................344
		Hydraulic Oil Exchange and Suction Strainer Cleaning................................................................................................346
		Check Alternator and Starter**......................................................................................................................348
		Check All Rubber Antivibration Shock Mounts.........................................................................................................348
		Perform and Record Results of Cycle Time Tests......................................................................................................348
		Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.....................................................................348
		Check, Adjust Valve Clearance**.....................................................................................................................348
		Check Head Bolt Torques.............................................................................................................................348
	4,000 Hour / Biennial Service...........................................................................................................................349
		Major Parts - Periodic Replacement..................................................................................................................349
	4,500 Hour / Biennial Service...........................................................................................................................350
		Clean Diesel Particulate Filter (DPF)...............................................................................................................350
	12,000 Hour / 6 Year Service............................................................................................................................351
		Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 (CEN)).........................................................................351
	Air-conditioning System.................................................................................................................................352
		Check Control Panel.................................................................................................................................352
		Check Air Conditioner Hoses.........................................................................................................................352
		Check Condenser.....................................................................................................................................352
		Check Magnetic Clutch...............................................................................................................................352
		Check Belt Tension..................................................................................................................................352
	Bolt and Nut Inspection.................................................................................................................................353
	Electrical System.......................................................................................................................................362
		Battery.............................................................................................................................................362
			Batteries in Cold Weather.......................................................................................................................362
			Inspection of Battery Electrolyte Level.........................................................................................................363
			Check Charging State............................................................................................................................363
			Check Battery Terminals.........................................................................................................................363
			Battery Replacement.............................................................................................................................363
		Fuses...............................................................................................................................................364
			Fuse Boxes......................................................................................................................................364
			Tilting Riser Inline Fuse.......................................................................................................................365
			Fuse Identification.............................................................................................................................366
	Engine Cooling System...................................................................................................................................367
		General.............................................................................................................................................367
			Types of Antifreeze.............................................................................................................................368
		Antifreeze Concentration Tables.....................................................................................................................369
		Electric Viscous Fan Clutch.........................................................................................................................370
			Removal and Installation of the Cooling Fan Assembly............................................................................................370
	Fuel Transfer Pump (Optional)...........................................................................................................................371
	Handling of Accumulator.................................................................................................................................374
	Track Tension...........................................................................................................................................375
	Venting and Priming Hydraulic System....................................................................................................................377
		Main System Pump....................................................................................................................................377
		Hydraulic Cylinders.................................................................................................................................377
		Swing Motor.........................................................................................................................................378
		Travel Motor........................................................................................................................................378
		General Venting.....................................................................................................................................378
	Maintenance in Special Conditions.......................................................................................................................379
Transportation..............................................................................................................................................381
	Loading and Unloading...................................................................................................................................381
		Warning for Counterweight and Front Attachment Removal..............................................................................................381
		Loading and Unloading Machine.......................................................................................................................385
	Lifting Machine.........................................................................................................................................389
Troubleshooting.............................................................................................................................................391
	Electrical System.......................................................................................................................................391
	Engine..................................................................................................................................................392
	Turbocharger............................................................................................................................................396
	Cooling Fan.............................................................................................................................................397
	Lubrication System......................................................................................................................................397
	Hydraulic System........................................................................................................................................398
	Air Compressor (Optional)...............................................................................................................................399
	Swing System............................................................................................................................................400
	Travel System...........................................................................................................................................400
	Elevating Cab...........................................................................................................................................401
	Tilting Riser...........................................................................................................................................401
Specification...............................................................................................................................................403
	Standard Specification..................................................................................................................................403
	Overall Dimensions......................................................................................................................................404
		Tilting Riser With One - Piece Boom.................................................................................................................404
		Elevating Cab With One - Piece Boom.................................................................................................................405
	Disassembled Parts, Dimension and Weight................................................................................................................406
		Components..........................................................................................................................................406
	Working Range...........................................................................................................................................409
		One - Piece Boom....................................................................................................................................409
		Material Handler Rated Lift Capacity Tables.........................................................................................................410
Index.......................................................................................................................................................415

DOOSAN DX225MH 3 OPERATION &MAINTENANCE MANUAL 950106-01406NA – PDF DOWNLOAD:

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