Doosan DX225LCA Track Excavator Service Repair Shop Manual

(S/N: 5167 and Up)
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This service manual PDF download for the DX225LCA Daewoo Doosan Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Daewoo Doosan Excavator DX225LCA
Serial Number 5167 and Up


TABLE OF CONTENTS :

Safety
Track Excavator Safety - P001716

Specifications
Specification for DX225LCA - SP001717

General Maintenance
General Maintenance Procedures - SP000016
Standard Torques - SP000813

Upper Structure
Cabin - SP000943
Counterweight - SP001617
Fuel Tank - SP001718
Fuel Transfer Pump - SP000021
Swing Bearing - SP000022
Swing Reduction Gear - SP001618

Lower Structure and Chassis
Track Assembly - SP001619

Engine and Drive Train
Drive Coupling (Main Pump) - SP000912

Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment - SP000913
Accumulator - SP000028
Center Joint (Swivel) - SP001620
Cylinders - SP000914
Swing Motor - SP000194
Travel Motor - SP001621
Gear Pump - SP000931
Main Control Valve - SP001024
Axial Piston Pump - SP000932
PTO Server - SP000933
Remote Control Valve (Work Lever / Joystick) - SP001646
Travel Control Valve (with Damper) - SP001647
Solenoid Valve Assembly - SP001622
Breaker EPPR Valve (Opt) - SP000192
Hydraulic Schematic (DX225LC/DX225LCA) - SP001689

Electrical System
Electrical System - SP001727
Electrical Schematic (DX225LCA) - SP001732

Attachments
Boom and Arm - SP000937
Bucket - SP000939


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Pub. No. : K1049156E
Total Pages : 792


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Table of Contents
Safety
Track Excavator Safety
Safety Precautions
Applicable Models
To the Operator of a DOOSAN Excavator
Learn the Signal Words Used with the Safety Alert Symbol
General Safety Essentials
Accessory Applications
Lifting Capacity Rating Configuration
Location of Safety Labels
Summary of Safety Precautions for Lifting in Digging Mode
Unauthorized Modifications
General Hazard Information
Safety Rules
Safety Features
Inside Operator's Compartment
Clothing and Personal Protective Items
Breathing Masks, Ear Protection May Be Required
Vibration Level Information
Recommendations for Limiting Vibrations
Mounting and Dismounting
Fuel, Oil and Hydraulic Fluid Fire Hazards
Precautions When Handling Fluids at High Temperature
Asbestos Dust Hazard Prevention
Injury from Work Equipment
Fire Extinguisher and First Aid Kit
Protection from Falling or Flying Objects
Attachment Precautions
Accumulator
Indoor Ventilation
Emergency Exit
Before Starting Engine
Work Site Precautions
Checks Before Starting Engine
Engine Starting
Before Operating Machine
Machine Operation
When Swinging or Changing Direction of Travel
Travel Precautions
Traveling on Slopes
Prohibited Operations
Precautions for Operation
Avoid High Voltage Cables
Protecting Cabin from Falling Object (Optional)
Operate Carefully on Snow, Ice and in Very Cold Temperatures
Operations on Slopes
Parking Machine
Never Let Anyone Ride on Attachment
Maintenance
Warning Tag
Clean Before Inspection or Maintenance
Proper Tools
Use of Lighting
Fire Prevention and Explosion Prevention
Burn Prevention
Welding Repairs
Warning for Counterweight and Front Attachment Removal
Precautions for Removal, Installation, and Storage of Attachments
Precautions When Working on Machine
Lock Inspection Covers
Crushing Prevention and Cutting Prevention
Track Tension Adjustments Require Caution
Supports and Blocking for Work Equipment
Action When Abnormality Is Found During Inspection
Precautions with High-pressure Lines, Tubes and Hoses
Waste Materials
Battery
Battery Hazard Prevention
Boost Starting or Charging Engine Batteries
Towing
Precautions When Towing
Shipping and Transportation
Obey State and Local Over-the-Road Regulations
Lifting With Sling
Specifications
Specification for DX225LCA
Safety Precautions
Applicable Models
General Description
Component Locations
General Dimensions
Working Range
General Specifications
Engine Performance Curves (Per DIN?6270 Standard)
Approximate Weight of Workload Materials
Performance Tests
Excavator Performance Standards
Test Conditions
Travel Speed and Travel Motor Balance (Steering Deviation) Tests
Speed Test
Travel Deviation
Swing Speed and Deceleration Force Test
Swing Speed Test
Swing Deceleration Force Test
Cylinder Performance Tests
Boom Cylinders Test
Arm Cylinder Test
Bucket Cylinder Test
Hydraulic Cylinder Natural Drop Test
Travel Motor Jack-up Test
General Maintenance
General Maintenance Procedures
Safety Precautions
Applicable Models
Welding Precautions and Guidelines
Hydraulic System - General Precautions
Maintenance Service and Repair Procedure
General Precautions
Hydraulic System Cleanliness and Oil Leaks
Maintenance Precautions for Hydraulic System Service
Oil Leakage Precautions
Cleaning and Inspection
General Guidelines
Bearing Inspection
Normal Bearing
Bent Cage
Galling
Abrasive Step Wear
Etching
Misalignment
Indentations
Fatigue Spalling
Brinelling
Cage Wear
Abrasive Roller Wear
Cracked Inner Race
Smears
Frettage
Heat Discoloration
Stain Discoloration
Standard Torques
Safety Precautions
Applicable Models
Torque Values for Standard Metric Fasteners
Torque Values for Standard U.S. Fasteners
Type 8 Phosphate Coated Hardware
Torque Values for Hose Clamps
Torque Values for Split Flanges
Torque Wrench Extension Tools
Torque Multiplication
Other Uses for Torque Wrench Extension Tools
Tightening Torque Specifications (Metric)
I. "Loctite" Fastener Adhesives
II. "Loctite" Pipe Thread Sealant
III. "Loctite" gasket/flange sealer
IV. "Loctite" retaining compounds
V. "Loctite" Adhesives
Upper Structure
Cabin
Safety Precautions
Applicable Models
Removal
Installation
Counterweight
Safety Precautions
Applicable Models
General
Warning for Counterweight and Front Attachment Removal
Removal
Installation
Fuel Tank
Safety Precautions
Applicable Models
General Description
Parts List
Specifications
Removal
Installation
Start-up Procedures
Fuel Transfer Pump
Safety Precautions
Applicable Models
General Description
Theory of Operation
Troubleshooting
Replacement of Rotor and Vane
Replacement of Rear Cover
Replacement of Armature
Swing Bearing
Safety Precautions
Applicable Models
Swing Bearing Maintenance
Operating Recommendation
Measuring Swing Bearing Axial Play
Measuring Bearing Lateral Play
Swing Bearing Basic Operation
Rebuilding Swing Bearing
Swing Reduction Gear
Safety Precautions
Applicable Models
General Description
Theory of Operation
Parts List
Specifications
Troubleshooting, Testing and Adjustment
Removal
Disassembly
Cleaning and Inspection (Wear Limits and Tolerances)
Reassembly
Shaft and S/R Bearing Heat?fit
Assembly of Carrier Subassemblies
Cleaning Carrier
Cleaning Planet Gear
Assembly of No. 1 Carrier
Assembly of No. 2 Carrier
Assembly of Main Case
Cleaning Casing and Other Parts
Assembly of Shaft and Pinion
Assembly of Seal and Bearing
Assembly of Ring Gear
Assembly of Carrier.
Assembly of the Motor
Installation
Start?up Procedures
Lower Structure and Chassis
Track Assembly
Safety Precautions
Applicable Models
General Description
Track Tension
Cleaning and Inspection (Wear Limits and Tolerances)
Track Shoe
Lower Roller
Upper Roller
Front Idler
Track Shoes and Links
Track Removal
Track Installation
Front Idler Roller
Parts List
Front Idler Roller Disassembly
Front Idler Roller Reassembly
Lower Roller
Parts List
Lower Roller Removal
Lower Roller Disassembly
Lower Roller Reassembly
Lower Roller Installation
Upper Roller
Parts List
Upper Roller Removal
Upper Roller Disassembly
Upper Roller Reassembly
Track Spring and Track Adjusting Cylinder
Parts List
Engine and Drive Train
Drive Coupling (Main Pump)
Safety Precautions
Applicable Models
Drive Coupling
Special Tools
Installation of Drive Coupling
Installation Procedure
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment
Safety Precautions
Applicable Models
Hydraulic System - General Notes
Hydraulic Schematic
General Notes
Operation of Working Components
Boom Operating Circuit
Boom Up Circuit
Boom Down Circuit
Arm Operating Circuit
Arm Crowd Circuit
Arm Dump Circuit
Bucket Operating Circuit
Bucket Crowd Circuit
Bucket Dump Circuit
Swing Operating Circuit
Right Swing Operating Circuit
Left Swing Operating Circuit
Swing Relief Valve and Makeup Valve
Travel Operating Circuit
Forward Travel Circuit
Reverse Travel Circuit
Procedural Troubleshooting Baseline Recommendations
Initial Checks and Tests to Establish Operating Condition of the Excavator
Triage Summary
Pilot Pressure
Adjustment and Testing
Power Mode Valve
Current Signal and Hydraulic Pressure Adjustments
Swing Priority Valve
Control Valve Pressure and Current Adjustments
Pressure Up Valve
Checks and Adjustments
Pump Input Power Control
Pump Regulator Adjustment
Flow Meter and Flow Meter Kit Installation and Testing
Installation and Testing Procedure
Swing System Troubleshooting
Precautions/Initial Checks
Swing Relief Valve Checking and Adjustment
Troubleshooting – Swing Gearbox
Troubleshooting – Hydraulic Problems
Troubleshooting – Control Valve
Troubleshooting – Travel Control Valve
Troubleshooting – Joystick Control Valve
Accumulator
Safety Precautions
Applicable Models
General Description
Specifications
Center Joint (Swivel)
Safety Precautions
Applicable Models
General Description
Parts List
Troubleshooting, Testing and Adjustment
Inspection
Testing
Disassembly
Reassembly
Cylinders
Safety Precautions
Applicable Models
General Description
Theory of Operation
Parts List
Special Tools and Materials
Piston Nut
Piston Jig
Steel Bushing Jig
Dust Wiper Jig
Slipper Seal Jig
Slipper Seal Straightening Jig
Disassembly
Reassembly
Swing Motor
Safety Precautions
Applicable Models
Operation Manual
Information on Marking
Specifications
Structure and Operational Principles
Structure
Operational Principles
Brake Subassembly
Cautions
Check Points
Rotation Direction
External Load on Shaft End
Active Oil and Temperature Range
Filter
Installation and Piping
Fillup and Air Discharge
Cautions During Start
Causes and Solutions of Problems
General Cautions.
How to Check Defects of Motor
Symptoms and Solutions of Problems
Maintenance Instructions
Disassembly and Assembly
Bolt Tightening Torque
Tools Used for Disassembly and Assembly
Disassembly
Assembly
Maintenance
References for Replacement of Worn Parts
Fixing References for Sliding Parts
Travel Motor
Safety Precautions
Applicable Models
TM40VD Operation Manual
General Specifications
Legend
Basic Structure and Diagram
Basic Structure of TM Motor
Operation Principles
Reducer
Hydraulic Motor (Brake Valve, Parking Brake, High and Low 2-Speed Shifting)
Cautions in Use
Fitting (Refer to the External Specifications Diagrams.)
Piping
Hydraulic Oil
Lubricating Oil
Maintenance
Troubleshooting
External Specifications Diagrams
Basic Structure and Diagrams
Assembly Cross Section
Parts List
TM40VD Maintenance Instructions
Precautions
Tools List for Disassembly and Reassembly
Standard Tools
Machined Tools
Disassembly Instructions
General Cautions
Disassembly procedure
Disassembling Hydraulic motor Part
Reassembly
General Precautions
Reassembly Procedure
Reassemble the Hydraulic Motor Part
Reassemble the Rear Flange Part (1)
The Reduction Gear Assembly
Checking Facts After Assembly
Testing
List of Seals
Gear Pump
Safety Precautions
Applicable Models
Single Gear Pump
Disassembly
Reassembly
Main Control Valve
Safety Precautions
Applicable Models
General Description
Theory of Operation
When All Spools are in Neutral
Single Operation
Compound Operation
Antidrift Valve
Main Relief Valve
Overload Relief Valve
Low-pressure Relief Valve
Parts List
Specifications
Troubleshooting, Testing and Adjustment
Troubleshooting
Overall Control Valve
Relief Valve
Overall Oil Pressure
Adjustment of Valves
Main Relief Valve
Overload Relief Valve
Disassembly
Caution in Disassembly
Disassembly of Main Spool Part
Disassembly of Arm 1 Para-turn Spool Part
Disassembly of Arm Regeneration Release Valve Part
Disassembly of Load Check Valve Part
Disassembly of Antidrift Valve Part
Disassembly of Relief Valve
Disassembly of Option Section Part
Disassembly of Other Plugs
Disassembly of Valve Housing Bolt
Disassembly of Main Relief Valve
Disassembly of Overload Relief Valve
Instruction of Disassembly and Assembly of Low-pressure Relief Valve
Cleaning and Inspection (Wear Limits and Tolerances)
Cleaning
Inspection
Reassembly
Caution on Assembly
Caution on Handling O-ring
Caution on Handling Spool
Method of Painting the Adhesives (screw part and arm screw part of parts requiring the adhesiveness)
Sequence of Subassembly
Spool Assembly (Main Spool)
Arm 1 Para-turn Spool Assembly
Antidrift Valve Assembly
Assembly Sequence of Main Body of the Control Valve
Assembly of Relief Valve
Assembly of Load Check Valve
Assembly of Antidrift Valve
Assembly of Option Section Part
Assembly of Arm Regeneration Release Valve
Assembly of Arm 1 Para-turn Spool
Assembly of Main Spool
Assembly of Other Plugs
Maintenance of Relief Valves
Reassembly of Main Relief Valve
Reassembly of Overload Relief Valve (69, Total of 6 Places)
Reassembly of Low-pressure Relief Valve (70, Total of 2 Places)
Installation
Start-up Procedures
Axial Piston Pump
Safety Precautions
Applicable Models
Pump Maintenance
Component Locations
Parts List
Tools
Tightening Torque
Disassembly
Reassembly
Pump Body Maintenance Standards
Change Standards of Worn Parts
Fix Standards of Cylinder Block, Valve Plate, and Swash Plate (Shoe Plate)
PTO Server
Safety Precautions
Applicable Models
Pump Maintenance
Disassembly
Reassembly
Maintenance Standards of Pump Body
Remote Control Valve (Work Lever / Joystick)
Safety Precautions
Applicable Models
General Description
Theory of Operation
Structure
Function
Parts List
Specifications
Performance
Torques
Tools and Materials
Disassembly
Cleaning and Inspection (Wear Limits and Tolerances)
Reassembly
Start-up Procedures
Travel Control Valve (with Damper)
Safety Precautions
Applicable Models
General Description
Theory of Operation
Pressure Reducing Valve
Operating Theory of Damper Mechanism
Causes of Faults and Measures
Parts List
Specification
Torques
Removal
Disassembly
Cleaning and Inspection (Wear Limits and Tolerances)
Reassembly
Installation
Start?up Procedures
Solenoid Valve Assembly
Safety Precautions
Applicable Models
5-Solenoid Valve
Parts List
Functions of 5-Solenoid Valve Assembly Package
This solenoid valve assembly package have the following functions.
Functions and Operations of Solenoid Valves
Detailed Functions and Operations of Solenoid Valves
Assembly Diagram and Tools Required
Cautions During Disassembly and Reassembly
Solenoid Valve Diagram
Check Points and Solutions for Problems
Checking of Pilot Pressure for Defects
2-Solenoid Valve
Parts List
Assembly Diagram and Tools Reguired
Cautions During Disassembly and Reassembly
Solenoid Valve Diagram
Troubleshooting Guide
Breaker EPPR Valve (Opt)
Safety Precautions
Applicable Models
Structure
Numbers and Names of Parts
Functions and Operation
Cautions for Operation
Maintenance Instructions
Maintenance
Bolt Tightening Torque
Tools Used for Disassembly and Assembly
Disassembly
Assembly
Hydraulic Schematic (DX225LC/ DX225LCA)
Safety Precautions
Applicable Models
DX225LC/DX225LCA
Electrical System
Electrical System
Safety Precautions
Applicable Models
Introduction
Electric Wire Color
Electrical Supply System
Engine Starting Circuit
Start Operation
After Start
Operation of the Start Circuit (2) ? Immediately After Start
Engine Preheating System
Engine Stop
Charging System
Monitoring System
Instrument Panel
Monitoring System Schematic
Operation
Instruments
Warning and Indicator Lights
Indication of Warning Lights
Indication of Multifunction Gauge and Letter Information Area
Initial Operation
Mode Selector Switch
Power Mode Switch
Auto Idle Switch
Graphic Information Area Display
Overview
Main Menus for the Graphic Display Area
Menu Selector Buttons
Main Menu
Language
Set Clock
Filter/Oil Info
Menu Display Order and Icon Explanation
Adjust Display
Set Password
Special Menu
Entering/Accessing and Exiting/Escaping Menus
Entering/Accessing Menus
Exiting/Escaping Menus
Special Menu Selections
Information of Machine Status
Failure Information
Information of Machine Operation
Machine Operation Info Screen
Electronic Hydraulic Control System (e?EPOS)
Control System Schematic
Power Mode Control
Operation
1. Power Mode
2. Standard Mode
3 Operation in case of failure in the control system (Aux mode operation
Power Mode Control ? Circuit Diagram
Work Mode Control
Work Mode Control ? Circuit Diagram
Engine Control System
Engine Control Dial
Engine Control Motor
Engine Control Circuit Diagram
Automatic Deceleration Control (Auto Idle Control)
Engine Overheat Protection System
Power Boost Mode
Operation
Power Boost Control ? Circuit Diagram
Automatic Travel Speed Control
Automatic Travel Speed Control ? Circuit Diagram
Adjust Engine Speed
Engine Throttle controller
Self?diagnostic Function
e?EPOS Controller
Air Conditioner System
Outline
Internal and External Filters
How to Check Internal Air Filter
How to Check External Air Filter
Air?Conditioning System Layout
Air Conditioner/heater Circuit Diagram
Air Conditioner/heater Unit
Air Flow Diagram
Door Open by Vent Modes
Main Components
Actuator ? Wind Direction Control
Actuator ? Temperature Control
Actuator ? Internal/external Air Exchange
Air Flow Control Module
Ambient Air Temperature Sensor
Sun Sensor
Control Panel
Appearance and Terminal Arrangement
Terminal Terms
Control Logic
Self Diagnosis
Ambient Temperature Display
Compressor
Receiver Dryer
Wiper System
Wiper Circuit
Wiper operation
Continuous operation
Intermittent operation
Lighting System
Lighting System Circuit Diagram
Kind of Light
Operation
Overload Warning Device
Overload Warning Device Circuit Diagram
Audio Controller
Audio Controller Circuit Diagram
Operations Via Audio Control Panel
Electrical Schematic (DX225LCA)
Safety Precautions
Applicable Models
DX225LCA
Attachments
Boom and Arm
Safety Precautions
Applicable Models
Front Attachment Pin Specifications
Front Attachment - Removal and Installation
Arm Removal Procedure
Boom Removal Procedure
Installation
Arm Installation Procedure
Boom Installation Procedure
Start-up Procedures
Bucket
Safety Precautions
Applicable Models
Bucket Tooth Inspection and Replacement
Bucket O-ring Replacement
Bucket Attachment, Removal and Reversal
Detaching the Bucket
Attaching the Bucket
Reversing the Bucket

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