Doosan DX225LCA Track Excavator Service Repair Workshop 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 :

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

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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
            
            –