Doosan DX225LL Excavator Log loader Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
DESCRIPTION:
Doosan DX225LL Excavator Log loader Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
Serial Number 5017 and Up
50106-00278CE
SAFETY DECALS:
- Safety decals are attached to the machine to alert the operator or maintenance person about potential hazards, the consequences of potential injury, and instructions and/or actions required to avoid the hazard.
- The location of the safety decals and the description of the decals are reviewed in the following section. Please become familiarized with all safety decals and their messages. Make sure that all the safety decals are in their correct location and legible.
- Clean or replace the safety decals if they are damaged, missing, or the texts and pictorials are not legible. When you clean the safety decals, use a soft cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety decals because this could loosen the adhesive that secures the decals to the machine.
- Remember, if a safety decal is attached to a part that is replaced, install a new safety decal on the replacement part. This machine uses safety decals with and without text. The type and number of safety decals can vary depending upon geographical regions and machine models.
Safety Decals With Text
- Safety decals with text consist of a signal word, pictorial and a text message panel. In some cases, a pictorial panel may not be part of the safety decal.
TABLE OF CONTENTS:
Doosan DX225LL Excavator Log loader Forestry Machine Operation & Maintenance Manual – PDF DOWNLOAD
DX225LL........................................................................................................................................................ 0 Table of Contents.......................................................................................................................................... 5 Safety..................................................................................................................................................... 9 To the Operator of a DOOSAN Forest Machine............................................................................................................. 9 Learn Signal Words Used with Safety Alert Symbol................................................................................................... 10 Safety Decals.......................................................................................................................................... 12 Information and Location for Safety Decals......................................................................................................... 14 Information and Location for Safety Decals (Continued)............................................................................................. 15 Summary of Safety Precautions for Lifting in Digging Mode.............................................................................................. 25 Unauthorized Modifications............................................................................................................................. 26 General Hazard Information............................................................................................................................. 26 Safety Rules....................................................................................................................................... 26 Safety Features.................................................................................................................................... 27 Inside Operator's Cabin............................................................................................................................ 27 Clothing and Personal Protective Items............................................................................................................. 28 Breathing Masks, Ear Protection May Be Required.................................................................................................... 28 Vibration Level Information........................................................................................................................ 28 Recommendations for Limiting Vibrations............................................................................................................ 29 Mounting and Dismounting........................................................................................................................... 30 Fuel, Oil and Hydraulic Fluid Fire Hazards......................................................................................................... 30 Precautions When Handling Fluids at High Temperature............................................................................................... 31 Asbestos Dust Hazard Prevention.................................................................................................................... 31 Injury from Work Equipment......................................................................................................................... 32 Fire Extinguisher and First Aid Kit................................................................................................................ 32 Protection from Falling or Flying Objects.......................................................................................................... 33 Attachment Precautions............................................................................................................................. 33 Accumulator........................................................................................................................................ 34 Indoor Ventilation................................................................................................................................. 34 Emergency Exit..................................................................................................................................... 34 Before Starting Engine................................................................................................................................. 35 Work Site Precautions.............................................................................................................................. 35 Checks Before Starting Engine...................................................................................................................... 36 Engine Starting.................................................................................................................................... 37 Before Operating Machine........................................................................................................................... 38 Seat Belt.......................................................................................................................................... 39 Machine Operation...................................................................................................................................... 40 When Swinging or Changing Direction of Travel...................................................................................................... 40 Travel Precautions................................................................................................................................. 41 Traveling on Slopes................................................................................................................................ 42 Prohibited Operations.............................................................................................................................. 42 Precautions for Operation.......................................................................................................................... 43 Avoid High-voltage Cables.......................................................................................................................... 44 Roll Over Protective Structure (ROPS).............................................................................................................. 45 ROPS Certification................................................................................................................................. 45 Operate Carefully on Snow, Ice and in Very Cold Temperatures....................................................................................... 46 Operations on Slopes............................................................................................................................... 46 Parking Machine.................................................................................................................................... 47 Never Let Anyone Ride on Attachment................................................................................................................ 47 Maintenance............................................................................................................................................ 0 Proper Tools....................................................................................................................................... 49 Use of Lighting.................................................................................................................................... 49 Fire Prevention and Explosion Prevention........................................................................................................... 49 Burn Prevention.................................................................................................................................... 50 Welding Repairs.................................................................................................................................... 51 Warning for Counterweight and Front Attachment Removal............................................................................................. 52 Precautions for Removal, Installation, and Storage of Attachments.................................................................................. 53 Precautions When Working on Machine................................................................................................................ 53 Lock Inspection Covers............................................................................................................................. 53 Prevention of Crushing and Cutting................................................................................................................. 53 Track Tension Adjustments Require Caution.......................................................................................................... 54 Supports and Blocking for Work Equipment........................................................................................................... 54 Action When Abnormality Is Found During Inspection................................................................................................. 54 Precautions with High-pressure Lines, Tubes and Hoses.............................................................................................. 55 Waste Materials.................................................................................................................................... 55 Hydraulic Cylinders, Pins and Bushings............................................................................................................. 56 Battery................................................................................................................................................ 57 Battery Hazard Prevention.......................................................................................................................... 57 Boost Starting or Charging Engine Batteries........................................................................................................ 58 Towing................................................................................................................................................. 59 Precautions When Towing............................................................................................................................ 59 Shipping and Transportation............................................................................................................................ 60 Obey State and Local Over-the-Road Regulations..................................................................................................... 60 Forest Machine Rated Lift Capacity Tables.............................................................................................................. 61 Operating Controls......................................................................................................................................... 65 Component Locations.................................................................................................................................... 66 Operator's Area........................................................................................................................................ 68 Operational Controls and Panels........................................................................................................................ 70 1. Starter Switch.................................................................................................................................. 72 2. Heater and Air Conditioner Control Panel........................................................................................................ 72 3. Power Socket For 12 Volt........................................................................................................................ 73 4. Cigarette Lighter............................................................................................................................... 73 5. Engine Emergency Stop Switch.................................................................................................................... 73 6. Engine Speed Control Dial....................................................................................................................... 74 7. Travel Speed Selector Switch.................................................................................................................... 74 8. Light Switch.................................................................................................................................... 74 9. Cabin Work Light Switch......................................................................................................................... 75 10. Audio Control Panel............................................................................................................................ 75 11. Wiper Control Panel............................................................................................................................ 76 12. Travel/Swing Alarm Switch...................................................................................................................... 77 13. Fuel Heater Switch (Optional).................................................................................................................. 78 14. Power Socket For 12 Volt (Optional)............................................................................................................ 78 15. Horn Button (Left-hand Work Lever)............................................................................................................. 78 16. Rotating Buttons............................................................................................................................... 79 17. Grapple Buttons................................................................................................................................ 79 18. Booster Button (Right-hand Work Lever)......................................................................................................... 79 Instrument Panel....................................................................................................................................... 0 7. Charge Warning.................................................................................................................................. 85 8. Engine Oil Pressure Warning..................................................................................................................... 85 12. Work Light Indicator........................................................................................................................... 87 13. Warning Light.................................................................................................................................. 87 Multifunction Gauge and Graphic Information............................................................................................................ 0 Communication Error Warning........................................................................................................................ 89 Engine Speed....................................................................................................................................... 89 Battery Voltage.................................................................................................................................... 89 Mode Selector Buttons.................................................................................................................................. 93 1. Power Mode Selector Button...................................................................................................................... 93 2. Economy Mode Selector Button.................................................................................................................... 93 3. Auto Idle Selector Button....................................................................................................................... 94 4. Flow Control Button (Not Used).................................................................................................................. 94 Operation Selection Display............................................................................................................................ 0 Camera Mode Selector Button........................................................................................................................106 Heater and Air Conditioner Control Panel...............................................................................................................107 Location of Controls and Vents.....................................................................................................................107 Control Panel......................................................................................................................................108 Memory Function....................................................................................................................................112 Additional Operating Instructions..................................................................................................................112 Miscellaneous Electrical Devices.......................................................................................................................114 Cabin Light........................................................................................................................................114 Pilot Cutoff Switch................................................................................................................................114 Circuit Breaker....................................................................................................................................114 Fusible Link.......................................................................................................................................115 Fuse Boxes.........................................................................................................................................115 Seat Adjustment........................................................................................................................................ 0 7. Storage Compartment.............................................................................................................................118 8. Left and Right Control Stand Adjustment.........................................................................................................118 Emergency Glass Breaking Tool..........................................................................................................................127 Operation..................................................................................................................................................129 To Handle a New Forest Machine.........................................................................................................................129 Lubrication and Filters............................................................................................................................130 Starting and Stopping the Engine.......................................................................................................................130 Inspection Before Starting Engine..................................................................................................................130 Operational Checks Before Starting Engine..........................................................................................................131 Starting Engine With a Booster Cable...............................................................................................................136 Hydraulic System Warm-up...........................................................................................................................138 Hydraulic System Warm-up - Cold Weather............................................................................................................139 Stopping Engine....................................................................................................................................140 Check and Confirmation After Stopping Engine.......................................................................................................141 Safety Lever...........................................................................................................................................142 Travel.................................................................................................................................................143 Automatic Travel Speed Control.....................................................................................................................144 Travel Control Lever Operation.....................................................................................................................145 General Travel Instructions........................................................................................................................146 Operating Instructions.................................................................................................................................149 Engine Speed Control...............................................................................................................................149 Mode Selection.....................................................................................................................................149 Work Levers (Joysticks) (ISO Pattern)..............................................................................................................151 Operating Precautions..................................................................................................................................153 Always Observe These Precautions...................................................................................................................155 Working in Water...................................................................................................................................156 Parking Forest Machine.................................................................................................................................157 Towing Procedure.......................................................................................................................................158 Lifting Objects........................................................................................................................................159 Operation Under Unusual Conditions.....................................................................................................................161 Operation In Extreme Cold..........................................................................................................................161 Operation in Extreme Heat..........................................................................................................................162 Operation in Dusty or Sandy Areas..................................................................................................................164 Operation in Rainy or Humid Conditions.............................................................................................................164 Operation in Salt Water Areas......................................................................................................................165 Operation at High Altitudes........................................................................................................................165 Inspection, Maintenance and Adjustment..................................................................................................................... 0 Preventive Maintenance................................................................................................................................. 0 Component Serial Numbers...........................................................................................................................169 Safety Precautions.................................................................................................................................169 Preliminary Work Machine Setup for Maintenance.........................................................................................................170 Table of Recommended Lubricants........................................................................................................................172 Coolant and Water for Dilution.....................................................................................................................174 Fluid Capacities.......................................................................................................................................175 Lubrication and Service Chart..........................................................................................................................175 Maintenance Intervals..................................................................................................................................178 10 Hour / Daily Service................................................................................................................................180 Grease Front Attachment Pins (for first 100 hours).................................................................................................180 Check Engine Oil Level.............................................................................................................................180 Check Level of Hydraulic Oil Tank..................................................................................................................181 Check for Leaks in Hydraulic System................................................................................................................182 Check Fuel Level...................................................................................................................................183 Check for Leaks in Fuel System.....................................................................................................................183 Check Fuel Prefilter and Drain Water As Required...................................................................................................184 Check Oil Level of Swing Reduction Device..........................................................................................................185 Clean Dust Net in Front of Oil Cooler and Intercooler..............................................................................................186 Check Cooling System and Refill As Required........................................................................................................186 Check Level of Window Washer Liquid................................................................................................................187 Inspect Cooling Fan Blade..........................................................................................................................187 Check Air Intake System............................................................................................................................188 Inspect Seat Belt for Proper Operation.............................................................................................................188 Inspect Structure for Cracks and Faulty Welds......................................................................................................188 Check the Operation of All Switches................................................................................................................188 Check the Operation of Pilot Cutoff Switch.........................................................................................................189 Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights......................................................190 Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds....190 Check Operation of All Controls....................................................................................................................190 50 Hour / Weekly Service...............................................................................................................................191 Perform All Daily Service Checks...................................................................................................................191 Grease Front Attachment Pins.......................................................................................................................191 Grease Swing Bearing...............................................................................................................................196 Drain Water and Sediment from Fuel Tank............................................................................................................197 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours)..................................................................197 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, Rollers, Idlers)...................................197 250 Hour / Monthly Service............................................................................................................................. 0 Check Engine Fan Belt Wear.........................................................................................................................199 Replace Hydraulic Oil Return Filter (After First 250 Hours)........................................................................................200 Change Pilot Filter (After First 250 Hours)........................................................................................................200 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear...........................................................................200 Check Fluid Levels in Batteries....................................................................................................................200 Inspect for Any Loose or Missing Nuts and Bolts....................................................................................................200 Inspect Fuel System Hose Clamps....................................................................................................................200 500 Hour / 3 Month Service.............................................................................................................................201 Perform All Daily, 50 and 250 Hour Service Checks..................................................................................................201 Grease Swing Gear and Pinion.......................................................................................................................201 Change Engine Oil and Filter.......................................................................................................................202 Clean Air-Conditioning Outer Filter................................................................................................................203 Check and Clean Air-Conditioning Inner Filter......................................................................................................204 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core............................................................205 Change of Fuel Prefilter...........................................................................................................................208 Change Fuel Filter.................................................................................................................................209 Check Oil Level in Travel Reduction Device (One on Each Side of Unit)..............................................................................210 Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours)...........................................................210 Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours).........................................................................210 1,000 Hour / 6 Month Service........................................................................................................................... 0 Change Swing Reduction Device Oil..................................................................................................................214 Change Air-Conditioning Outer Filter...............................................................................................................215 Change Air-Conditioning Inner Filter...............................................................................................................215 Check Air Conditioner Refrigerant..................................................................................................................216 Change Fuel Cap Filter.............................................................................................................................217 Check and Adjust Engine **.........................................................................................................................218 2,000 Hour / Yearly Service............................................................................................................................219 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks......................................................................................219 Change Oil in Travel Reduction Device (One on Each Side of Unit)...................................................................................219 Hydraulic Oil Exchange and Suction Strainer Cleaning...............................................................................................223 Check Alternator and Starter**.....................................................................................................................225 Check All Rubber Antivibration Shock Mounts........................................................................................................225 Perform and Record the Results of the Cycle Time Tests.............................................................................................225 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage....................................................................225 Check, Adjust Valve Clearance **...................................................................................................................225 Check Head Bolt Torques............................................................................................................................225 4,000 Hour / Biennial Service..........................................................................................................................226 Major Parts - Periodic Replacement.................................................................................................................226 12,000 Hour / 6 Year Service...........................................................................................................................227 Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN)..........................................................................227 Air-Conditioning System................................................................................................................................228 Check Control Panel................................................................................................................................228 Check Air Conditioner Hoses........................................................................................................................228 Check Condenser....................................................................................................................................228 Check Magnetic Clutch..............................................................................................................................228 Check Belt Tension.................................................................................................................................228 Bolt and Nut Inspection................................................................................................................................229 Electrical System......................................................................................................................................237 Battery............................................................................................................................................237 Fuses..............................................................................................................................................239 Engine Cooling System..................................................................................................................................241 General............................................................................................................................................241 Antifreeze Concentration Tables....................................................................................................................243 Table of Standards for Allowed Tap Water...........................................................................................................243 Fuel Transfer Pump (Optional)..........................................................................................................................244 Handling of Accumulator................................................................................................................................247 Track Tension..........................................................................................................................................248 Venting and Priming Hydraulic System...................................................................................................................250 Main System Pump...................................................................................................................................250 Hydraulic Cylinders................................................................................................................................250 Swing Motor........................................................................................................................................251 Travel Motor.......................................................................................................................................251 General Venting....................................................................................................................................251 Long Term Storage......................................................................................................................................252 Before Storage.....................................................................................................................................252 During Storage.....................................................................................................................................253 After Storage......................................................................................................................................253 Maintenance in Special Conditions......................................................................................................................254 Transportation.............................................................................................................................................255 Loading and Unloading..................................................................................................................................255 Warning for Counterweight and Front Attachment Removal.............................................................................................255 Lifting Machine........................................................................................................................................259 Troubleshooting............................................................................................................................................261 Electrical System......................................................................................................................................261 Engine.................................................................................................................................................262 Hydraulic System.......................................................................................................................................264 Swing System...........................................................................................................................................265 Travel System..........................................................................................................................................265 Specification..............................................................................................................................................267 Standard Specification.................................................................................................................................267 Overall Dimensions.....................................................................................................................................268 Approximate Weight of Workload Materials...............................................................................................................271 Index......................................................................................................................................................273
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R.D
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Very efficient