Doosan DX225LC Manuals

Manuals and User Guides for Doosan DX225LC. We have 4 Doosan DX225LC manuals available for free PDF download: Instructions Manual, Manual, Shop Manual

Doosan DX225LC Instructions Manual (810 pages)

Track Excavator

Brand: Doosan | Category: Excavators | Size: 49.93 MB

Table of Contents

11
- Track Excavator Safety
  13
- Safety Precautions
  13
- Applicable Models
  13
- To the Operator of a DOOSAN Excavator
  14
- General Safety Essentials
  17
- Location of Safety Labels
  18
- Summary of Safety Precautions for Lifting in Digging Mode
  18
- Unauthorized Modifications
  19
- General Hazard Information
  19
- Before Starting Engine
  28
- Machine Operation
  32
- Maintenance
  39
- Battery
  47
- Towing
  49
- Shipping and Transportation
  50
- Lifting with Sling
  50
Table of Contents

55
- Applicable Models
  57
- Safety Precautions
  57
- General Description
  59
- Component Locations
  60
- General Dimensions
  62
- Working Range
  64
- General Specifications
  66
- Engine Performance Curves (Per DIN 6270 Standard)
  68
- Approximate Weight of Workload Materials
  70
- Performance Tests
  72
- Excavator Performance Standards
  73
- Test Conditions
  73
- Travel Speed and Travel Motor Balance (Steering Deviation) Tests
  73
- Swing Speed and Deceleration Force Test
  75
- Cylinder Performance Tests
  77
Table of Contents

83
Table of Contents

103
- Applicable Models
  105
- Safety Precautions
  105
- Torque Values for Standard Metric Fasteners
  106
- Torque Values for Standard U.S. Fasteners
  107
- Type 8 Phosphate Coated Hardware
  109
- Torque Values for Hose Clamps
  110
- Torque Values for Split Flanges
  111
- Torque Multiplication
  112
- Torque Wrench Extension Tools
  112
- Other Uses for Torque Wrench Extension Tools
  113
- Tightening Torque Specifications (Metric)
  114
Table of Contents

121
- Applicable Models
  123
- Cabin
  123
- Safety Precautions
  123
- Removal
  124
- Installation
  128
Table of Contents

133
- Applicable Models
  135
- Safety Precautions
  135
- General
  136
- Warning for Counterweight and Front Attachment Removal6
  136
- Removal
  138
- Installation
  139
Table of Contents

143
- Applicable Models
  145
- Safety Precautions
  145
- General Description
  146
- Parts List
  146
- Specifications
  147
- Removal
  148
- Installation
  152
- Start-Up Procedures
  155
Table of Contents

159
- Applicable Models
  161
- Safety Precautions
  161
- General Description
  162
- Theory of Operation
  162
- Replacement of Rotor and Vane
  163
- Troubleshooting
  163
- Replacement of Armature
  164
- Replacement of Rear Cover
  164
Table of Contents

167
- Applicable Models
  169
- Safety Precautions
  169
- Measuring Bearing Lateral Play
  170
- Measuring Swing Bearing Axial Play
  170
- Operating Recommendation
  170
- Swing Bearing Maintenance
  170
- Disassembly
  171
- Swing Bearing Basic Operation
  171
- Assembly
  173
Table of Contents

177
- Applicable Models
  179
- Safety Precautions
  179
- General Description
  181
- Theory of Operation
  181
- Parts List
  182
- Specifications
  183
- Troubleshooting, Testing and Adjustment
  184
- Removal
  185
- Disassembly
  186
- Cleaning and Inspection (Wear Limits and Tolerances)
  195
- Assembly of Carrier Subassemblies
  196
- Reassembly
  196
- Shaft and S/R Bearing Heat-Fit
  196
- Assembly of Main Case
  202
- Assembly of Motor
  218
- Installation
  222
- Start-Up Procedures
  223
Table of Contents

229
- Applicable Models
  231
- Safety Precautions
  231
- General Description
  232
- Track Tension
  233
- Cleaning and Inspection
  235
- Track Shoe
  236
- Lower Roller
  238
- Upper Roller
  239
- Front Idler
  240
- Track Removal
  241
- Track Shoes and Links
  241
- Track Installation
  242
- Front Idler Roller
  244
- Parts List
  244
- Front Idler Roller Disassembly
  245
- Front Idler Roller Reassembly
  247
- Lower Roller
  248
- Parts List
  248
- Lower Roller Disassembly
  249
- Lower Roller Removal
  249
- Lower Roller Reassembly
  250
- Lower Roller Installation
  251
- Parts List
  252
- Upper Roller
  252
- Upper Roller Disassembly
  253
- Upper Roller Removal
  253
- Upper Roller Reassembly
  255
- Parts List
  256
- Track Spring and Track Adjusting Cylinder
  256
Table of Contents

261
- Applicable Models
  263
- Safety Precautions
  263
- Drive Coupling
  264
- Special Tools
  265
- Drive Coupling Installation
  266
- Installation Procedure
  268
Hydraulic System Troubleshooting, Testing and Adjustment/Hydraulic System Troubleshooting, Testing and Adjustment

273
- Hydraulic System Troubleshooting, Testing and Adjustment
  274
- Applicable Models
  275
- Safety Precautions
  275
- General Notes
  276
- Hydraulic System - General Notes
  276
- Boom down Circuit
  279
- Boom Operating Circuit
  279
- Boom up Circuit
  279
- Operation of Working Components
  279
- Arm Crowd Circuit
  280
- Arm Dump Circuit
  280
- Arm Operating Circuit
  280
- Bucket Crowd Circuit
  281
- Bucket Dump Circuit
  281
- Bucket Operating Circuit
  281
- Swing Operating Circuit
  281
- Left Swing Operating Circuit
  282
- Right Swing Operating Circuit
  282
- Swing Relief Valve and Makeup Valve
  282
- Travel Operating Circuit
  282
- Forward Travel Circuit
  283
- Reverse Travel Circuit
  283
- Initial Checks and Tests to Establish Operating Condition of the Excavator
  284
- Procedural Troubleshooting Baseline Recommendations
  284
- Adjustment and Testing
  286
- Pilot Pressure
  286
- Current Signal and Hydraulic Pressure Adjustments
  287
- Power Mode Valve
  287
- Checks and Adjustments
  288
- Pressure up Valve
  288
- Pump Input Power Control
  290
- Pump Regulator Adjustment
  290
- Flow Meter and Flow Meter Kit Installation and Testing
  293
- Precautions/Initial Checks
  295
- Swing System Troubleshooting
  295
- Swing Relief Valve Checking and Adjustment
  296
- Troubleshooting - Swing Gearbox
  298
- Troubleshooting - Hydraulic Problems
  299
- Troubleshooting - Control Valve
  301
- Troubleshooting - Travel Control Valve
  302
- Troubleshooting - Joystick Control Valve
  303
Table of Contents

307
- Applicable Models
  309
- Safety Precautions
  309
- General Description
  310
- Specifications
  312
Table of Contents

315
- Applicable Models
  317
- Safety Precautions
  317
- General Description
  318
- Parts List
  319
- Inspection
  320
- Testing
  320
- Troubleshooting, Testing and Adjustment
  320
- Disassembly
  321
- Reassembly
  324
Table of Contents

329
- Applicable Models
  331
- Safety Precautions
  331
- General Description
  332
- Theory of Operation
  332
- Parts List
  334
- Piston Nut
  336
- Special Tools and Materials
  336
- Piston Jig
  338
- Steel Bushing Jig
  340
- Dust Wiper Jig
  342
- Slipper Seal Jig
  344
- Slipper Seal Straightening Jig
  346
- Disassembly
  348
- Reassembly
  353
Table of Contents

359
- Applicable Models
  361
- Safety Precautions
  361
- General Description
  362
- Theory of Operation
  362
- Makeup Check Valve
  365
- Operation of Swing Reactionless Valve
  365
- Operation of Time Delay Valve
  365
- Parts List
  366
- Specifications
  368
- Torques
  368
- Tools
  369
- Tools and Materials
  369
- General Precautions
  370
- How to Check Faults of Hydraulic Motor
  370
- Troubleshooting
  370
- Troubleshooting, Testing and Adjustment
  370
- Disassembly
  372
- General Cautions
  372
- Cleaning and Inspection (Wear Limits and Tolerances)
  379
- Assembly
  380
- General Cautions
  380
- Reassembly
  380
- Assembly of Cylinder Block Assembly Subassembly
  383
- Assembly of Rear Cover Assembly Subassembly
  387
- Air Pressure Test
  393
- Oil Leakage Check
  393
Table of Contents

397
- Applicable Models
  399
- Safety Precautions
  399
- General Description
  401
- Structure
  401
- Operation Basics
  402
- Parts List
  408
- Connection Torque
  410
- Specifications
  410
- General Precautions
  412
- How to Check Faults of Hydraulic Motor
  412
- Troubleshooting
  412
- Troubleshooting, Testing and Adjustment
  412
- Disassembly
  414
- General Cautions
  414
- Disassembly of Cylinder Subassembly
  420
- Cleaning and Inspection
  422
- Maintenance Standard
  422
- Tolerances)
  422
- General Cautions
  426
- Reassembly
  426
- Reassembly of Drive Shaft Subassembly
  426
- Assembly of Valve Casing Subassembly
  427
- Assembly of Cylinder Subassembly
  431
- Assembly of Motor Body
  433
Table of Contents

441
- Applicable Models
  443
- Safety Precautions
  443
- Axial Piston Pump
  444
- General Description
  444
- Model Number Designation
  444
- Theory of Operation
  445
- Parts List
  446
- Torques
  448
- Tools
  449
- Troubleshooting, Testing and Adjustment
  451
- Disassembly
  453
- Cleaning and Inspection (Wear Limits and Tolerances)
  456
- Worn Part Replacement Criteria
  456
- Correction Criteria for Cylinder, Valve Plate and
  457
- Plate (Shoe Plate)
  457
- Reassembly
  458
- Cautions During Starting Operation
  462
- Oil Filling and Air Venting
  462
- Start-Up Procedures
  462
- General Description
  463
- Model Number Designation
  463
- Regulator for Axial Piston Pump
  463
- Parts List
  464
- Outline
  465
- Functional Explanations
  467
- Specifications
  467
Table of Contents

487
- Applicable Models
  489
- Gear Pump
  489
- Safety Precautions
  489
- Disassembly
  490
- Single Gear Pump
  490
- Reassembly
  492
- Disassembly
  496
- Double Gear Pump
  496
- Reassembly
  498
Table of Contents

505
- Parts List
  540
- Specifications
  545
- Troubleshooting
  546
- Troubleshooting, Testing and Adjustment
  546
- Adjustment of Valves
  547
- Disassembly
  549
- Cleaning
  559
- Cleaning and Inspection (Wear Limits and Tolerances)
  559
- Inspection
  559
- Caution on Assembly
  560
- Reassembly
  560
- Sequence of Subassembly
  561
- Maintenance of Relief Valves
  567
- Installation
  570
- Start-Up Procedures
  570
Table of Contents

573
- Applicable Models
  575
- Safety Precautions
  575
- General Description
  577
- Theory of Operation
  577
- Parts List
  578
- Specifications
  580
- Tools and Materials
  580
- Torques
  580
- Disassembly
  581
- Cleaning and Inspection
  585
- Reassembly
  585
- Tolerances)
  585
- Start-Up Procedures
  592
Table of Contents

621
- Applicable Models
  623
- Safety Precautions
  623
- 5-Solenoid Valve
  624
- Parts List
  624
- Functions of 5-Solenoid Valve Assembly
  625
- Assembly Diagram and Tools Required
  628
- Cautions During Disassembly and Reassembly
  629
- Solenoid Valve Diagram
  630
- Check Points and Solutions for Problems
  631
- 2-Solenoid Valve
  632
- Parts List
  632
- Assembly Diagram and Tools Required
  633
- Cautions During Disassembly and Reassembly
  634
- Solenoid Valve Diagram
  635
Table of Contents

639
- Applicable Models
  641
- Breaker EPPR Valve (Opt)
  641
- Safety Precautions
  641
- Numbers and Names of Parts
  642
- Structure
  642
- Cautions for Operation
  643
- Functions and Operation
  643
- Maintenance
  644
- Maintenance Instructions
  644
- Disassembly
  645
- Assembly
  646
Table of Contents

661
- Applicable Models
  664
- Safety Precautions
  664
- Introduction
  665
- Electrical Supply System
  666
- Engine Starting Circuit
  668
- Engine Preheating System
  672
- Engine Stop
  674
- Charging System
  676
- Monitoring System
  677
- Operation
  682
- Warning and Indicator Lights
  684
- Initial Operation
  687
- Mode Selector Switch
  687
- Graphic Information Area Display
  688
- Main Menu
  690
- Special Menu
  695
- Electronic Hydraulic Control System (E-EPOS)
  712
- Power Mode Control
  714
- Power Mode Control - Circuit Diagram
  719
- Engine Control System
  720
- Engine Control Motor
  721
- Engine Control Dial
  722
- Engine Control Circuit Diagram
  723
- Automatic Deceleration Control (Auto Idle Control)
  724
- Engine Overheat Protection System
  726
- Power Boost Mode
  728
- Automatic Travel Speed Control
  730
- Self-Diagnostic Function
  733
- Air Conditioner System
  735
- Troubleshooting
  755
- Weight of R134A Gas Used in Machines
  757
- Refrigerant System Repairs
  758
- Wiper System
  766
- Lighting System
  768
- Overload Warning Device
  770
- Audio Controller
  771
Table of Contents

785
- Applicable Models
  787
- Boom and Arm
  787
- Safety Precautions
  787
- Front Attachment Pin Specifications
  788
- Dx300Lc
  789
- Dx340Lc / Dx350Lc
  790
- Dx420Lc
  791
- Dx480Lc / Dx520Lc
  792
- Arm Removal Procedure
  793
- Front Attachment - Removal and Installation
  793
- Boom Removal Procedure
  795
- Arm Installation Procedure
  796
- Boom Installation Procedure
  796
- Installation
  796
- Start-Up Procedures
  797
- Applicable Models
  803
- Bucket
  803
- Safety Precautions
  803
- Bucket Tooth Inspection and Replacement
  804
- Bucket O-Ring Replacement
  805
- Bucket Shimming Procedures
  807
- New Bucket Installation
  807
- Attaching the Bucket
  809
- Bucket Attachment, Removal and Reversal
  809
- Detaching the Bucket
  809
- Reversing the Bucket
  810

Doosan DX225LC Manual (136 pages)

Brand: Doosan | Category: Excavators | Size: 3.32 MB

Table of Contents
4
Safety Precautions
8
Applicable Models
8
Introduction
10
Electrical Supply System
11
Engine Starting Circuit
13
Start Operation
13
After Start
15
Engine Preheating System
17
Engine Stop
19
Charging System
21
Monitoring System
22
Instrument Panel
23
Monitoring System Schematic
25
Operation
27
Instruments
27
Warning and Indicator Lights
29
Indication of Warning Lights
29
Indication of Multifunction Gauge and Letter Information Area
30
Initial Operation
32
Mode Selector Switch
32
Graphic Information Area Display
33
Overview
33
Main Menus for the Graphic Display Area
34
Menu Selector Buttons
34
Main Menu
35
Language
35
Set Clock
36
Filter/Oil Info
36
Adjust Display
37
Set Password
38
Special Menu
39
Entering/Accessing and Exiting/Escaping Menus
39
Special Menu Selections
40
Electronic Hydraulic Control System (E-EPOS)
57
Control System Schematic
57
Power Mode Control
59
Operation
61
Power Mode Control - Circuit Diagram
65
Work Mode Control
67
Operation
68
Work Mode Control - Circuit Diagram
69
Engine Control System
70
Engine Control Dial
71
Engine Control Circuit Diagram
73
Automatic Deceleration Control (Auto Idle Control)
75
Reference Number
75
Engine Overheat Protection System
77
Instrument Panel
77
Engine Controller
77
E-EPOS Controller
77
Power Boost Mode
79
Operation
79
Power Boost Control - Circuit Diagram
81
Battery
81
Battery Relay
81
Automatic Travel Speed Control
83
Automatic Travel Speed Control - Circuit Diagram
85
Self-Diagnostic Function
86
E-EPOS Controller
86
Air Conditioner System
88
Outline
88
Internal and External Filters
89
Air-Conditioning System Layout
91
Air Conditioner/Heater Circuit Diagram
92
Air Conditioner/Heater Unit
93
Ambient Air Temperature Sensor
99
Sun Sensor
100
Control Panel
100
Compressor
108
Receiver Dryer
108
Troubleshooting
109
Weight of R134A Gas Used in Machines
111
Refrigerant System Repairs
112
Refrigerant Safe Handling Procedures
112
Repair and Replacement Procedure
113
Refrigerant Recovery
115
Vacuuming Refrigerant System
115
Leakage Check
117
Refrigerant Charging
117
Inspecting System for Leakage
119
Wiper System
120
Wiper Circuit
120
Wiper Operation
121
Lighting System
123
Lighting System Circuit Diagram
123
Kind of Light
124
Operation
124
Overload Warning Device
125
Overload Warning Device Circuit Diagram
125
Audio Controller
126
Audio Controller Circuit Diagram
126
Electrical Schematic (DX180LC/DX225LC/DX225NLC/DX255LC)
131
Safety Precautions
132
Applicable Models
132
Dx180Lc/Dx225Lc/Dx225Nlc/Dx255Lc
135

Doosan DX225LC Shop Manual (110 pages)

Serial Number 5001 and Up

Brand: Doosan | Category: Excavators | Size: 9.64 MB

Table of Contents

8
- Specifications
  3
- Track Excavator Safety
  6
- Safety Precautions
  9
- Applicable Models
  9
- To the Operator of a DOOSAN Excavator
  10
- General Safety Essentials
  10
  - Specifications
    11
- Location of Safety Labels
  15
- Summary of Safety Precautions for Lifting in Digging Mode
  16
- Unauthorized Modifications
  17
- General Hazard Information
  17
  - Cabin
    18
  - Emergency Exit
    25
- Before Starting Engine
  26
- Machine Operation
  30
  - Traveling on Slopes
    32
  - Prohibited Operations
    32
  - Parking Machine
    36
- Maintenance
  37
  - Specifications
    38
- Battery
  46
- Towing
  48
- Shipping and Transportation
  49
- Lifting with Sling
  49
  - Specifications
    50
Specification

52
- Specifications
  52
- Applicable Models
  53
- Safety Precautions
  53
- General Description
  54
- Component Locations
  55
  - Swing Bearing
    56
- General Dimensions
  57
- Working Range
  58
- General Specifications
  60
- Engine Performance Curves (Per DIN 6270 Standard)
  62
- Approximate Weight of Workload Materials
  64
- Performance Tests
  66
- Excavator Performance Standards
  67
General Maintenance Procedures

75
- Applicable Models
  76
- Safety Precautions
  76
- Welding Precautions and Guidelines
  77
- Hydraulic System - General Precautions
  78
  - Cylinders
    78
- Maintenance Service and Repair Procedure
  80
  - General Precautions
    80
  - Swing Motor
    80
- Hydraulic System Cleanliness and Oil Leaks
  81
  - Maintenance Precautions for Hydraulic System Service
    81
  - Oil Leakage Precautions
    82
- Cleaning and Inspection
  83
  - General Guidelines
    83
  - Bearing Inspection
    84
Standard Torques

92
- Applicable Models
  93
- Safety Precautions
  93
- Standard Torques
  93
- Torque Values for Standard Metric Fasteners
  94
- Torque Values for Standard U.S. Fasteners
  95
- Type 8 Phosphate Coated Hardware
  97
- Torque Values for Hose Clamps
  98
- Torque Values for Split Flanges
  99
- Torque Wrench Extension Tools
  100
  - Torque Multiplication
    100
  - Other Uses for Torque Wrench Extension Tools
    101
  - Tightening Torque Specifications (Metric)
    101
  - Bucket
    109

Doosan DX225LC Manual (63 pages)

Travel Control Valve (with Damper)

Brand: Doosan | Category: Excavators | Size: 15.32 MB

Table of Contents
3
Safety Precautions
5
Applicable Models
5
General Description
7
Theory of Operation
7
Pressure Reducing Valve
8
Operating Theory of Damper Mechanism
9
Causes of Faults and Measures
11
Parts List
12
Specification
14
Torques
14
Removal
15
Disassembly
16
Cleaning and Inspection (Wear Limits and Tolerances)
18
Reassembly
19
Installation
24
Start-Up Procedures
25
Safety Precautions
31
Applicable Models
31
5-Solenoid Valve
32
Parts List
32
Functions of 5-Solenoid Valve Assembly Package
33
Assembly Diagram and Tools Required
35
Cautions During Disassembly and Reassembly
36
Solenoid Valve Diagram
37
Check Points and Solutions for Problems
38
2-Solenoid Valve
39
Parts List
39
Assembly Diagram and Tools Reguired
40
Cautions During Disassembly and Reassembly
41
Solenoid Valve Diagram
42
Troubleshooting Guide
42
Safety Precautions
47
Applicable Models
47
Structure
49
Numbers and Names of Parts
49
Functions and Operation
50
Cautions for Operation
50
Maintenance Instructions
51
Maintenance
51
Disassembly
52
Assembly
53
Hydraulic Schematic
58
Dx225Lc Dx225Lca
59
Safety Precautions
59
Applicable Models
59
Dx225Lc/Dx225Lca
61

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