Doosan DX225LL Excavator Log loader Operation & Maintenance Manual K1045080E-1 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX225LL Excavator Log loader Operation & Maintenance Manual K1045080E-1 – PDF DOWNLOAD
Serial Number 5001 thru 5016
K1045080E-1
GENERAL HAZARD INFORMATION:
Safety Rules
- Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
- Do not operate the machine if you are not feeling well, if you are taking medication that makes you feel sleepy, if you have been drinking, or if you are suffering from emotional problems.
- These problems will interfere with your sense of judgement in emergencies and may cause accidents. When working with another operator or with a person on work site traffic duty, be sure that all personnel know the nature of the work and understand all hand signals that are to be used. Always observe strictly any other rules related to safety.
Safety Features
- Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as safety lock lever and the seat belt, and use them properly.
- Never remove any safety features. Always keep them in good operating condition. Failure to use safety features according to the instructions in the Operation and Maintenance Manual could result in serious
TABLE OF CONTENTS:
Doosan DX225LL Excavator Log loader Operation & Maintenance Manual K1045080E-1 – PDF DOWNLOAD
Table of Contents............................................................................................... 5 Safety.......................................................................................................... 9 To the Operator of a DOOSAN Forest Machine.................................................................. 9 Learn the Signal Words Used with the Safety Alert Symbol................................................ 11 Location of Safety Labels................................................................................... 12 1. Warnings for Operation, Inspection and Maintenance (19000688, 19000092)............................ 13 2. Warnings for High Voltage (19000689, 19000096)..................................................... 13 3. Warnings When Opening a Front Window (21903388, 19000093).......................................... 14 4. Warnings for a Highpressure Cylinder (19000122).................................................... 14 5. Warnings When Adjusting Track Tension (21903386A, 19000521)........................................ 15 6. Warnings for Leaving Operator's Seat (19000693, 19000094).......................................... 15 7. Warnings for Batteries Maintenance (21902533A, 19000100)........................................... 16 8. Warnings for High Temperature Hydraulic Oil (19000691A, 19000097).................................. 16 9. Warnings for Hot Coolant (19000692, 19000097)...................................................... 17 10. Warnings for ECU of Engine (K1012583)............................................................... 17 11. Warnings for Rotating Parts (19000694, 19000095, 19000557)....................................... 18 12. Warning Tag Used When Inspection and Maintenance (19000695A, 19000098A)......................... 18 13. Warning for a Hot Surface (19000648A).............................................................. 19 14. Caution for Hood (19000522A)....................................................................... 19 15. Keep Out of the Swing Area (21903379A, K1008571)................................................... 20 16. Warnings for Front Attachments (19000652).......................................................... 20 17. Warning for Intrusion Hazard (21903444)............................................................ 21 18. Warning for Power Lines (21903450A)................................................................ 21 Summary of Safety Precautions for Lifting in Digging Mode................................................... 22 Unauthorized Modifications.................................................................................. 23 General Hazard Information.................................................................................. 23 Safety Rules............................................................................................ 23 Safety Features......................................................................................... 23 Inside Operator's Compartment........................................................................... 24 Clothing and Personal Protective Items.................................................................. 25 Breathing Masks, Ear Protection May Be Required......................................................... 25 Vibration Level Information............................................................................. 25 Recommendations for Limiting Vibrations................................................................. 25 Mounting and Dismounting................................................................................ 26 Fuel, Oil and Hydraulic Fluid Fire Hazards.............................................................. 27 Precautions When Handling Fluids at High Temperature.................................................... 27 Asbestos Dust Hazard Prevention......................................................................... 28 Injury from Work Equipment.............................................................................. 28 Fire Extinguisher and First Aid Kit..................................................................... 28 Protection from Falling or Flying Objects............................................................... 29 Attachment Precautions.................................................................................. 30 Accumulator............................................................................................. 30 Indoor Ventilation...................................................................................... 31 Emergency Exit.......................................................................................... 31 Before Starting Engine...................................................................................... 32 Work Site Precautions................................................................................... 32 Checks Before Starting Engine........................................................................... 33 Engine Starting......................................................................................... 33 Before Operating Machine................................................................................ 34 Machine Operation........................................................................................... 36 When Swinging or Changing Direction of Travel........................................................... 36 Travel Precautions...................................................................................... 37 Traveling on Slopes..................................................................................... 38 Prohibited Operations................................................................................... 38 Precautions for Operation............................................................................... 39 Avoid High Voltage Cables............................................................................... 40 Operate Carefully on Snow, Ice and in Very Cold Temperatures............................................ 40 Operations on Slopes.................................................................................... 41 Parking Machine......................................................................................... 41 Never Let Anyone Ride on Attachment..................................................................... 41 Maintenance................................................................................................. 42 Warning Tag............................................................................................. 42 Clean Before Inspection or Maintenance.................................................................. 42 Proper Tools............................................................................................ 43 Use of Lighting......................................................................................... 43 Fire Prevention and Explosion Prevention................................................................ 43 Burn Prevention......................................................................................... 44 Welding Repairs......................................................................................... 45 Warning for Counterweight and Front Attachment Removal.................................................. 46 Precautions for Removal, Installation, and Storage of Attachments....................................... 47 Precautions When Working on Machine..................................................................... 47 Lock Inspection Covers.................................................................................. 47 Crushing Prevention and Cutting Prevention.............................................................. 47 Track Tension Adjustments Require Caution............................................................... 48 Supports and Blocking for Work Equipment................................................................ 48 Action When Abnormality Is Found During Inspection...................................................... 48 Precautions with Highpressure Lines, Tubes and Hoses................................................... 49 Waste Materials......................................................................................... 50 Hydraulic Cylinders, Pins and Bushings.................................................................. 50 Battery..................................................................................................... 51 Battery Hazard Prevention............................................................................... 51 Boost Starting or Charging Engine Batteries............................................................. 52 Towing...................................................................................................... 53 Precautions When Towing................................................................................. 53 Shipping and Transportation................................................................................. 54 Obey State and Local OvertheRoad Regulations.......................................................... 54 Forest Machine Rated Lift Capacity Tables................................................................... 55 Operating Controls.............................................................................................. 59 Component Locations......................................................................................... 60 Operator's Area............................................................................................. 62 Operational Controls and Panels............................................................................. 64 1. Starter Switch....................................................................................... 66 2. Engine Speed Control Dial............................................................................ 66 3. Auxiliary Mode Switch................................................................................ 67 4. Engine Emergency Stop Switch......................................................................... 67 5. Audio Control Panel.................................................................................. 67 6. Travel Speed Selector Switch......................................................................... 69 7. Light Switch......................................................................................... 69 8. Cabin Work Light Switch.............................................................................. 69 9. Blank (Empty Switch Socket).......................................................................... 70 12. Heater and Air Conditioner Control Panel............................................................ 70 13. Wiper Switch Panel.................................................................................. 70 14. Cigarette Lighter................................................................................... 71 15. Power Socket for 12 Volt............................................................................ 72 16. Travel Alarm Switch................................................................................. 72 18. Fuel Heater Switch (Optional)....................................................................... 72 19. Seat Warmer Switch (Optional)....................................................................... 73 20. Horn Button (Lefthand Work Lever).................................................................. 73 21. Rotating Buttons.................................................................................... 73 22. Booster Button (Righthand Work Lever).............................................................. 74 23. Grapple Buttons..................................................................................... 74 24. Instrument Panel.................................................................................... 74 25. Safety Lever........................................................................................ 75 26. Photo Sensor........................................................................................ 75 Instrument Panel............................................................................................ 76 Functional check........................................................................................ 77 Password Activated...................................................................................... 77 1. Fuel Gauge........................................................................................... 78 2. Engine Coolant Temperature Gauge..................................................................... 78 3. Hydraulic Oil Temperature Gauge...................................................................... 79 4. Multifunction Gauge and Graphic Information Area..................................................... 79 5. Digital Clock........................................................................................ 79 6. Hour Meter........................................................................................... 80 7. Charge Warning Light................................................................................. 80 8. Engine Oil Pressure Warning Light.................................................................... 80 9. Engine Coolant Temperature Warning Light............................................................. 81 10. Engine Check Warning Light.......................................................................... 81 11. Preheating Indicator Light.......................................................................... 82 12. Work Light Indicator Light.......................................................................... 82 Multifunction Gauge and Graphic Information................................................................. 83 Communication Indicator................................................................................. 83 Communication Error Warning............................................................................. 84 Engine Speed............................................................................................ 84 Battery Voltage......................................................................................... 84 Front Hydraulic Pump Pressure........................................................................... 85 Rear Hydraulic Pump Pressure............................................................................ 85 Abnormal State Warning Symbols.......................................................................... 85 Mode Selector Buttons....................................................................................... 88 1. Power Mode Selector Button........................................................................... 88 2. Trenching Mode Selector Button....................................................................... 88 3. Auto Idle Selector Button............................................................................ 89 4. Flow Control Button.................................................................................. 89 Setting Main Menu........................................................................................... 90 1. Up Arrow Button...................................................................................... 90 2. Down Arrow Button.................................................................................... 91 3. Display Selector Button (ESC Escape)............................................................... 91 4. SelectionButton..................................................................................... 91 Display Selection and Escaping.......................................................................... 92 Main Menu............................................................................................... 92 Language................................................................................................ 93 Set Clock............................................................................................... 93 Filter / Oil Info....................................................................................... 94 Adjust Display.......................................................................................... 96 Set Password (Lock and Unlock).......................................................................... 97 Heater and Air Conditioner Control Panel.................................................................... 99 Location of Controls and Vents.......................................................................... 99 Control Panel...........................................................................................100 Memory Function.........................................................................................105 Additional Operating Instructions.......................................................................105 Stereo......................................................................................................106 Stereo..................................................................................................106 CD Player (Optional)....................................................................................106 Miscellaneous Electrical Devices............................................................................107 Cabin Light.............................................................................................107 Pilot Cutoff Switch.....................................................................................107 Circuit Breaker.........................................................................................107 Fusible Link............................................................................................108 Fuse Boxes..............................................................................................108 Seat Adjustment.............................................................................................109 1. Forward / Backward Adjustment........................................................................109 2. Seat Tilt and Height Adjustment......................................................................109 3. Suspension Adjustment................................................................................109 4. Reclining Position Adjustment........................................................................110 5. Armrest Angle Adjustment.............................................................................110 6. Lumbar Support Adjustment............................................................................110 7. Headrest.............................................................................................110 8. Seat Belt............................................................................................111 9. Seat Backpocket.....................................................................................112 10. Left and Right Control Stand Adjustment.............................................................112 11. Left and Right Control Stand Height Adjustment......................................................112 12. Air Suspension Seat (Optional)......................................................................112 13. Heating the Operator's Seat (Optional)..............................................................113 Ceiling Cover...............................................................................................113 Opening the Ceiling Cover...............................................................................113 Closing the Ceiling Cover...............................................................................113 Front Windows...............................................................................................114 Front Upper Window......................................................................................114 Front Bottom Window.....................................................................................115 Doors and Access Covers.....................................................................................116 Door Side Latch.........................................................................................116 Cabin Riser Access Door.................................................................................116 Tilt Cab....................................................................................................117 Cabin Storage Compartments..................................................................................117 Ashtray.....................................................................................................118 Sun Visor...................................................................................................118 Hanger......................................................................................................119 Cup Holder..................................................................................................119 Door Window Holder..........................................................................................119 Emergency Glass Breaking Tool...............................................................................120 Miscellaneous Access Covers and Doors.......................................................................120 Side Door...............................................................................................120 Battery Box Door........................................................................................120 Engine Cover............................................................................................121 Operation.......................................................................................................123 To Handle a New Forest Machine..............................................................................123 Lubrication and Filters.................................................................................124 Starting and Stopping the Engine............................................................................124 Inspection Before Starting Engine.......................................................................124 Operational Checks Before Starting Engine...............................................................125 Engine Start............................................................................................126 Cold Weather Starting...................................................................................128 Starting Engine With a Booster Cable....................................................................129 Hydraulic System Warmup................................................................................131 Hydraulic System Warmup – Cold Weather.................................................................132 Engine Shut Down........................................................................................133 Check and Confirmation After Stopping Engine............................................................134 Safety Lever................................................................................................135 Travel......................................................................................................136 Automatic Travel Speed Control..........................................................................136 Travel Control Lever Operation..........................................................................138 General Travel Instructions.............................................................................139 Operating Instructions......................................................................................142 Engine Speed Control....................................................................................142 Mode Selection..........................................................................................142 Work Levers (Joysticks) (ISO Style).....................................................................144 Operating Precautions.......................................................................................146 Always Observe These Precautions........................................................................148 Working in Water........................................................................................149 Parking Forest Machine......................................................................................150 Towing Procedure............................................................................................151 Operating Techniques........................................................................................152 Lifting.................................................................................................152 Operation Under Unusual Conditions..........................................................................154 Operation In Extreme Cold...............................................................................154 Operation in Extreme Heat...............................................................................155 Operation in Dusty or Sandy Areas.......................................................................156 Operation in Rainy or Humid Conditions..................................................................156 Operation in Salt Water Areas...........................................................................157 Operation at High Altitudes.............................................................................157 Inspection, Maintenance and Adjustment..........................................................................159 Preventive Maintenance......................................................................................159 Product Identification Number (P. I. N.) Location.......................................................160 Component Serial Numbers................................................................................160 Safety Precautions......................................................................................161 Preliminary Work Machine Setup for Maintenance..............................................................162 Table of Recommended Lubricants.............................................................................164 Fluid Capacities............................................................................................166 Lubrication and Service Chart...............................................................................166 Maintenance Intervals.......................................................................................170 10 Hour / Daily Service.....................................................................................172 Grease Front Attachment Pins (for first 100 hours)......................................................172 Check Engine Oil Level..................................................................................172 Check Level of Hydraulic Oil Tank.......................................................................173 Check for Leaks in Hydraulic System.....................................................................174 Check Fuel Level........................................................................................174 Check for Leaks in Fuel System..........................................................................175 Check Fuel Prefilter and Drain Water As Required........................................................175 Check Oil Level of Swing Reduction Device...............................................................176 Clean Dust Net in Front of Oil Cooler and Intercooler...................................................177 Check Cooling System and Refill As Required.............................................................178 Check Level of Window Washer Liquid.....................................................................178 Inspect Cooling Fan Blade...............................................................................179 Check Air Intake System.................................................................................179 Inspect Seat Belt for Proper Operation..................................................................179 Inspect the Structure for Cracks and Faulty Welds.......................................................180 Check the Operation of All Switches.....................................................................180 Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights.......180 Start Engine, Check Starting Ability, and Observe Exhaust Color at Startup and at Normal Operati.......180 Check Operation of All Controls.........................................................................181 50 Hour / Weekly Service....................................................................................182 Perform All Daily Service Checks........................................................................182 Grease Front Attachment Pins............................................................................182 Grease Swing Bearing....................................................................................188 Drain Water and Sediment from Fuel Tank.................................................................188 Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours).......................188 Change Engine Oil and Filter (After First 50 Hours).....................................................188 Inspect the Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links, Shoes, R.......188 250 Hour / Monthly Service..................................................................................189 Perform All Daily and 50 Hour Service Checks............................................................189 Change Swing Reduction Device Oil (Drain and Refill After First 250 Hours)..............................189 Check Engine Fan Belt Tension...........................................................................189 Check Engine Fan Belt Wear..............................................................................190 Check Oil Level in Travel Reduction Device (One on Each Side of Unit)...................................191 Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 250 Hours)................191 Replace Hydraulic Oil Return Filter (After First 250 Hours).............................................191 Change Pilot Filter (After First 250 Hours).............................................................191 Inspect Pins and Bushings of the Front End Attachments for Signs of Wear................................192 Check Fluid Levels in Batteries and Battery Charge Levels...............................................192 Inspect for Any Loose or Missing Nuts and Bolts.........................................................192 Inspect Fuel System Hose Clamps.........................................................................192 500 Hour / 3 Month Service..................................................................................193 Perform All Daily, 50 and 250 Hour Service Checks.......................................................193 Grease Swing Gear and Pinion............................................................................193 Change Engine Oil and Filter............................................................................194 Clean AirConditioning Outer Filter.....................................................................195 Check and Clean AirConditioning Inner Filter...........................................................196 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core.................197 Clean Outer Filter of Air Cleaner.......................................................................198 Change of Fuel Prefilter................................................................................200 Change Fuel Filter......................................................................................201 1,000 Hour / 6 Month Service................................................................................202 Perform All Daily, 50, 250 and 500 Hour Service Checks..................................................202 Grease Swing Reduction Device...........................................................................202 Change Pilot Filter.....................................................................................204 Change Oil in Travel Reduction Device (One on Each Side of Unit)........................................205 Change Air Breather Filter..............................................................................205 Change AirConditioning Outer Filter....................................................................206 Check Air Conditioner Refrigerant.......................................................................207 Check and Adjust Engine **..............................................................................207 2,000 Hour / Yearly Service.................................................................................208 Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks...........................................208 Change Swing Reduction Device Oil.......................................................................208 Replace Outer and Inner Air Cleaner Elements............................................................209 Change Radiator Coolant.................................................................................210 Hydraulic Oil Exchange and Suction Strainer Cleaning....................................................211 Check Alternator and Starter**..........................................................................213 Check All Rubber Antivibration Shock Mounts.............................................................213 Perform and Record the Results of the Cycle Time Tests..................................................213 Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage.........................213 Check, Adjust Valve Clearance **........................................................................213 Check Head Bolt Torques.................................................................................213 4,000 Hour / Biennial Service...............................................................................214 Major Parts Periodic Replacement......................................................................214 12,000 Hour / Six Year Service..............................................................................215 Hose Inservice Lifetime Limit (European Standard ISO8331 and EN982CEN)...............................215 AirConditioning System.....................................................................................216 Check Control Panel.....................................................................................216 Check Air Conditioner Hoses.............................................................................216 Check Condenser.........................................................................................216 Check Magnetic Clutch...................................................................................216 Check Belt Tension......................................................................................216 Bolt and Nut Inspection.....................................................................................217 Electrical System...........................................................................................224 Battery.................................................................................................224 Fuses...................................................................................................225 Engine Cooling System.......................................................................................228 General.................................................................................................228 Antifreeze Concentration Tables.........................................................................229 Fuel Transfer Pump (Optional)...............................................................................230 Handling of Accumulator.....................................................................................233 Track Tension...............................................................................................234 Venting and Priming Hydraulic System........................................................................236 Main System Pump........................................................................................236 Hydraulic Cylinders.....................................................................................236 Swing Motor.............................................................................................237 Travel Motor............................................................................................237 General Venting.........................................................................................237 Long Term Storage...........................................................................................238 Maintenance in Special Conditions...........................................................................239 Transportation..................................................................................................241 Loading and Unloading.......................................................................................241 Warning for Counterweight and Front Attachment Removal..................................................241 Lifting With Sling..........................................................................................245 Troubleshooting.................................................................................................247 Electrical System...........................................................................................247 Engine......................................................................................................248 Hydraulic System............................................................................................250 Swing System................................................................................................251 Travel System...............................................................................................251 Specification...................................................................................................253 Standard Specification......................................................................................253 Overall Dimensions..........................................................................................254 Working Range...............................................................................................256 Approximate Weight of Workload Materials....................................................................257 Index...........................................................................................................259
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