Doosan DX225LCA Excavator Shop Manual – Serial 5167 and Up (Pub. K1049156E) PDF Download

Description

Doosan DX225LCA Excavator Shop Manual – Serial 5167 and Up (K1049156E)

This is the complete factory-issued Doosan DX225LCA Shop Manual, Publication No. K1049156E, covering the DX225LCA track excavator for serial number 5167 and up. The Doosan DX225LCA Shop Manual runs 792 pages and is organized into individually numbered service sections (SP numbers) exactly as Doosan issued them, so every system on the excavator is documented in one searchable PDF instead of scattered binder inserts.

File Details

• Manual Type: Shop Manual
• Brand / Model: Doosan DX225LCA
• Applicable Serial Number Range: 5167 and Up
• Publication Number: K1049156E
• Language: English
• Page Count: 792 pages
• File Format: PDF
• Copyright: 2008 Doosan

Chapters Covered

The DX225LCA Shop Manual is broken into the following sections, matching the original table of contents:

• Safety
  • Track Excavator Safety
• Specifications
  • Specification for DX225LCA (general dimensions, working range, general specifications, engine performance curves, performance tests)
• General Maintenance
  • General Maintenance Procedures
  • Standard Torques
• Upper Structure
  • Cabin
  • Counterweight
  • Fuel Tank
  • Fuel Transfer Pump
  • Swing Bearing
  • Swing Reduction Gear
• Lower Structure and Chassis
  • Track Assembly
• Engine and Drive Train
  • Drive Coupling (Main Pump)
• Hydraulics
  • Hydraulic System Troubleshooting, Testing and Adjustment
  • Accumulator
  • Center Joint (Swivel)
  • Cylinders
  • Swing Motor
  • Travel Motor
  • Gear Pump
  • Main Control Valve
  • Axial Piston Pump
  • PTO Server
  • Remote Control Valve (Work Lever / Joystick)
  • Travel Control Valve (with Damper)
  • Solenoid Valve Assembly
  • Breaker EPPR Valve (Opt)
  • Hydraulic Schematic (DX225LC/DX225LCA)
  Complete PDF Bookmark Tree

  Complete Bookmarks

  The complete bookmarks in the “Doosan DX225LCA Excavator Shop Manual – Serial 5167 and Up (Pub. K1049156E) PDF Download” are as follows:

  Table of Contentsp. 5

  +Safetyp. 7

  +Track Excavator Safetyp. 9

  Safety Precautionsp. 13

  Applicable Modelsp. 13

  +To the Operator of a DOOSAN Excavatorp. 15

  Learn the Signal Words Used with the Safety Alert Symbolp. 17

  +General Safety Essentialsp. 18

  Accessory Applicationsp. 18

  Lifting Capacity Rating Configurationp. 18

  Location of Safety Labelsp. 19

  Summary of Safety Precautions for Lifting in Digging Modep. 19

  Unauthorized Modificationsp. 20

  +General Hazard Informationp. 20

  Safety Rulesp. 20

  Safety Featuresp. 21

  Inside Operator's Compartmentp. 21

  Clothing and Personal Protective Itemsp. 22

  Breathing Masks, Ear Protection May Be Requiredp. 22

  Vibration Level Informationp. 22

  Recommendations for Limiting Vibrationsp. 23

  Mounting and Dismountingp. 24

  Fuel, Oil and Hydraulic Fluid Fire Hazardsp. 24

  Precautions When Handling Fluids at High Temperaturep. 25

  Asbestos Dust Hazard Preventionp. 25

  Injury from Work Equipmentp. 26

  Fire Extinguisher and First Aid Kitp. 26

  Protection from Falling or Flying Objectsp. 27

  Attachment Precautionsp. 27

  Accumulatorp. 28

  Indoor Ventilationp. 28

  Emergency Exitp. 29

  +Before Starting Enginep. 29

  Work Site Precautionsp. 29

  Checks Before Starting Enginep. 30

  Engine Startingp. 31

  Before Operating Machinep. 32

  +Machine Operationp. 33

  When Swinging or Changing Direction of Travelp. 33

  Travel Precautionsp. 34

  Traveling on Slopesp. 35

  Prohibited Operationsp. 35

  Precautions for Operationp. 36

  Avoid High Voltage Cablesp. 37

  Protecting Cabin from Falling Object (Optional)p. 37

  Operate Carefully on Snow, Ice and in Very Cold Temperaturesp. 38

  Operations on Slopesp. 38

  Parking Machinep. 39

  Never Let Anyone Ride on Attachmentp. 39

  +Maintenancep. 40

  Warning Tagp. 40

  Clean Before Inspection or Maintenancep. 40

  Proper Toolsp. 41

  Use of Lightingp. 41

  Fire Prevention and Explosion Preventionp. 41

  Burn Preventionp. 42

  Welding Repairsp. 43

  Warning for Counterweight and Front Attachment Removalp. 43

  Precautions for Removal, Installation, and Storage of Attachmentsp. 44

  Precautions When Working on Machinep. 44

  Lock Inspection Coversp. 44

  Crushing Prevention and Cutting Preventionp. 44

  Track Tension Adjustments Require Cautionp. 45

  Supports and Blocking for Work Equipmentp. 45

  Action When Abnormality Is Found During Inspectionp. 45

  Precautions with High-pressure Lines, Tubes and Hosesp. 46

  Waste Materialsp. 47

  +Batteryp. 48

  Battery Hazard Preventionp. 48

  Boost Starting or Charging Engine Batteriesp. 49

  +Towingp. 50

  Precautions When Towingp. 50

  +Shipping and Transportationp. 51

  Obey State and Local Over-the-Road Regulationsp. 51

  Lifting With Slingp. 51

  +Specificationsp. 53

  +Specification for DX225LCAp. 55

  Safety Precautionsp. 59

  Applicable Modelsp. 59

  General Descriptionp. 61

  Component Locationsp. 62

  General Dimensionsp. 64

  Working Rangep. 65

  General Specificationsp. 67

  Engine Performance Curves (Per DIN6270 Standard)p. 69

  Approximate Weight of Workload Materialsp. 71

  Performance Testsp. 73

  +Excavator Performance Standardsp. 74

  Test Conditionsp. 74

  +Travel Speed and Travel Motor Balance (Steering Deviation) Testsp. 74

  Speed Testp. 74

  Travel Deviationp. 76

  +Swing Speed and Deceleration Force Testp. 76

  Swing Speed Testp. 76

  Swing Deceleration Force Testp. 77

  +Cylinder Performance Testsp. 78

  Boom Cylinders Testp. 78

  Arm Cylinder Testp. 78

  Bucket Cylinder Testp. 78

  Hydraulic Cylinder Natural Drop Testp. 78

  Travel Motor Jack-up Testp. 78

  +General Maintenancep. 81

  +General Maintenance Proceduresp. 83

  Safety Precautionsp. 87

  Applicable Modelsp. 87

  Welding Precautions and Guidelinesp. 88

  Hydraulic System – General Precautionsp. 89

  +Maintenance Service and Repair Procedurep. 91

  General Precautionsp. 91

  +Hydraulic System Cleanliness and Oil Leaksp. 92

  Maintenance Precautions for Hydraulic System Servicep. 92

  Oil Leakage Precautionsp. 93

  +Cleaning and Inspectionp. 94

  General Guidelinesp. 94

  +Bearing Inspectionp. 95

  Normal Bearingp. 96

  Bent Cagep. 96

  Gallingp. 97

  Abrasive Step Wearp. 97

  Etchingp. 98

  Misalignmentp. 98

  Indentationsp. 98

  Fatigue Spallingp. 99

  Brinellingp. 99

  Cage Wearp. 99

  Abrasive Roller Wearp. 100

  Cracked Inner Racep. 100

  Smearsp. 100

  Frettagep. 101

  Heat Discolorationp. 101

  Stain Discolorationp. 101

  +Standard Torquesp. 103

  Safety Precautionsp. 107

  Applicable Modelsp. 107

  Torque Values for Standard Metric Fastenersp. 108

  Torque Values for Standard U.S. Fastenersp. 109

  Type 8 Phosphate Coated Hardwarep. 111

  Torque Values for Hose Clampsp. 112

  Torque Values for Split Flangesp. 113

  +Torque Wrench Extension Toolsp. 114

  Torque Multiplicationp. 114

  Other Uses for Torque Wrench Extension Toolsp. 115

  +Tightening Torque Specifications (Metric)p. 116

  I. "Loctite" Fastener Adhesivesp. 117

  II. "Loctite" Pipe Thread Sealantp. 117

  III. "Loctite" gasket/flange sealerp. 117

  IV. "Loctite" retaining compoundsp. 118

  V. "Loctite" Adhesivesp. 118

  +Upper Structurep. 119

  +Cabinp. 121

  Safety Precautionsp. 125

  Applicable Modelsp. 125

  Removalp. 127

  Installationp. 131

  +Counterweightp. 135

  Safety Precautionsp. 139

  Applicable Modelsp. 139

  +Generalp. 141

  Warning for Counterweight and Front Attachment Removalp. 141

  Removalp. 143

  Installationp. 144

  +Fuel Tankp. 145

  Safety Precautionsp. 149

  Applicable Modelsp. 149

  +General Descriptionp. 150

  Parts Listp. 150

  Specificationsp. 151

  Removalp. 152

  Installationp. 157

  Start-up Proceduresp. 160

  +Fuel Transfer Pumpp. 161

  Safety Precautionsp. 165

  Applicable Modelsp. 165

  +General Descriptionp. 167

  Theory of Operationp. 167

  Troubleshootingp. 168

  Replacement of Rotor and Vanep. 168

  Replacement of Rear Coverp. 169

  Replacement of Armaturep. 169

  +Swing Bearingp. 171

  Safety Precautionsp. 175

  Applicable Modelsp. 175

  +Swing Bearing Maintenancep. 177

  Operating Recommendationp. 177

  Measuring Swing Bearing Axial Playp. 177

  Measuring Bearing Lateral Playp. 177

  Swing Bearing Basic Operationp. 178

  Rebuilding Swing Bearingp. 178

  +Swing Reduction Gearp. 181

  Safety Precautionsp. 185

  Applicable Modelsp. 185

  +General Descriptionp. 187

  Theory of Operationp. 187

  Parts Listp. 188

  Specificationsp. 189

  Troubleshooting, Testing and Adjustmentp. 190

  Removalp. 191

  Disassemblyp. 192

  Cleaning and Inspection (Wear Limits and Tolerances)p. 198

  +Reassemblyp. 199

  Shaft and S/R Bearing Heatfitp. 199

  +Assembly of Carrier Subassembliesp. 200

  Cleaning Carrierp. 200

  Cleaning Planet Gearp. 200

  Assembly of No. 1 Carrierp. 201

  Assembly of No. 2 Carrierp. 203

  +Assembly of Main Casep. 206

  Cleaning Casing and Other Partsp. 206

  Assembly of Shaft and Pinionp. 207

  Assembly of Seal and Bearingp. 208

  Assembly of Ring Gearp. 213

  Assembly of Carrier.p. 214

  Assembly of the Motorp. 217

  Installationp. 223

  Startup Proceduresp. 223

  +Lower Structure and Chassisp. 225

  +Track Assemblyp. 227

  Safety Precautionsp. 231

  Applicable Modelsp. 231

  General Descriptionp. 233

  Track Tensionp. 233

  +Cleaning and Inspection (Wear Limits and Tolerances)p. 236

  Track Shoep. 238

  Lower Rollerp. 240

  Upper Rollerp. 241

  Front Idlerp. 242

  +Track Shoes and Linksp. 243

  Track Removalp. 243

  Track Installationp. 244

  +Front Idler Rollerp. 246

  Parts Listp. 246

  Front Idler Roller Disassemblyp. 247

  Front Idler Roller Reassemblyp. 249

  +Lower Rollerp. 250

  Parts Listp. 250

  Lower Roller Removalp. 251

  Lower Roller Disassemblyp. 251

  Lower Roller Reassemblyp. 252

  Lower Roller Installationp. 253

  +Upper Rollerp. 254

  Parts Listp. 254

  Upper Roller Removalp. 255

  Upper Roller Disassemblyp. 255

  Upper Roller Reassemblyp. 257

  +Track Spring and Track Adjusting Cylinderp. 258

  Parts Listp. 258

  +Engine and Drive Trainp. 261

  +Drive Coupling (Main Pump)p. 263

  Safety Precautionsp. 267

  Applicable Modelsp. 267

  Drive Couplingp. 269

  Special Toolsp. 270

  +Installation of Drive Couplingp. 271

  Installation Procedurep. 272

  +Hydraulicsp. 275

  +Hydraulic System Troubleshooting, Testing and Adjustmentp. 277

  Safety Precautionsp. 281

  Applicable Modelsp. 281

  Hydraulic System – General Notesp. 282

  +Hydraulic Schematicp. 283

  General Notesp. 283

  +Operation of Working Componentsp. 285

  Boom Operating Circuitp. 285

  Boom Up Circuitp. 285

  Boom Down Circuitp. 285

  Arm Operating Circuitp. 286

  Arm Crowd Circuitp. 286

  Arm Dump Circuitp. 286

  Bucket Operating Circuitp. 287

  Bucket Crowd Circuitp. 287

  Bucket Dump Circuitp. 287

  Swing Operating Circuitp. 287

  Right Swing Operating Circuitp. 288

  Left Swing Operating Circuitp. 288

  Swing Relief Valve and Makeup Valvep. 288

  Travel Operating Circuitp. 288

  Forward Travel Circuitp. 289

  Reverse Travel Circuitp. 289

  +Procedural Troubleshooting Baseline Recommendationsp. 290

  +Initial Checks and Tests to Establish Operating Condition of the Excavatorp. 290

  Triage Summaryp. 290

  +Pilot Pressurep. 292

  Adjustment and Testingp. 292

  +Power Mode Valvep. 293

  Current Signal and Hydraulic Pressure Adjustmentsp. 293

  +Swing Priority Valvep. 294

  Control Valve Pressure and Current Adjustmentsp. 294

  +Pressure Up Valvep. 295

  Checks and Adjustmentsp. 295

  +Pump Input Power Controlp. 297

  Pump Regulator Adjustmentp. 297

  +Flow Meter and Flow Meter Kit Installation and Testingp. 300

  Installation and Testing Procedurep. 300

  +Swing System Troubleshootingp. 302

  Precautions/Initial Checksp. 302

  Swing Relief Valve Checking and Adjustmentp. 303

  Troubleshooting – Swing Gearboxp. 305

  Troubleshooting – Hydraulic Problemsp. 306

  Troubleshooting – Control Valvep. 308

  Troubleshooting – Travel Control Valvep. 309

  Troubleshooting – Joystick Control Valvep. 310

  +Accumulatorp. 311

  Safety Precautionsp. 315

  Applicable Modelsp. 315

  +General Descriptionp. 317

  Specificationsp. 319

  +Center Joint (Swivel)p. 321

  Safety Precautionsp. 325

  Applicable Modelsp. 325

  +General Descriptionp. 327

  Parts Listp. 328

  +Troubleshooting, Testing and Adjustmentp. 329

  Inspectionp. 329

  Testingp. 329

  Disassemblyp. 330

  Reassemblyp. 333

  +Cylindersp. 335

  Safety Precautionsp. 339

  Applicable Modelsp. 339

  +General Descriptionp. 341

  Theory of Operationp. 341

  Parts Listp. 344

  +Special Tools and Materialsp. 346

  Piston Nutp. 346

  Piston Jigp. 348

  Steel Bushing Jigp. 350

  Dust Wiper Jigp. 352

  Slipper Seal Jigp. 354

  Slipper Seal Straightening Jigp. 356

  Disassemblyp. 358

  Reassemblyp. 363

  +Swing Motorp. 367

  Safety Precautionsp. 371

  Applicable Modelsp. 371

  +Operation Manualp. 373

  Information on Markingp. 373

  Specificationsp. 374

  +Structure and Operational Principlesp. 375

  Structurep. 375

  Operational Principlesp. 377

  Brake Subassemblyp. 381

  +Cautionsp. 382

  Check Pointsp. 382

  Rotation Directionp. 382

  External Load on Shaft Endp. 383

  Active Oil and Temperature Rangep. 383

  Filterp. 384

  Installation and Pipingp. 385

  Fillup and Air Dischargep. 385

  Cautions During Startp. 385

  Causes and Solutions of Problemsp. 386

  General Cautions.p. 386

  How to Check Defects of Motorp. 386

  Symptoms and Solutions of Problemsp. 387

  +Maintenance Instructionsp. 389

  +Disassembly and Assemblyp. 389

  Bolt Tightening Torquep. 389

  Tools Used for Disassembly and Assemblyp. 389

  Disassemblyp. 391

  Assemblyp. 395

  +Maintenancep. 401

  References for Replacement of Worn Partsp. 401

  Fixing References for Sliding Partsp. 401

  +Travel Motorp. 403

  Safety Precautionsp. 407

  Applicable Modelsp. 407

  +TM40VD Operation Manualp. 408

  General Specificationsp. 408

  Legendp. 409

  +Basic Structure and Diagramp. 410

  Basic Structure of TM Motorp. 410

  +Operation Principlesp. 411

  Reducerp. 411

  Hydraulic Motor (Brake Valve, Parking Brake, High and Low 2-Speed Shifting)p. 412

  +Cautions in Usep. 418

  Fitting (Refer to the External Specifications Diagrams.)p. 418

  Pipingp. 418

  Hydraulic Oilp. 419

  Lubricating Oilp. 420

  Maintenancep. 421

  Troubleshootingp. 422

  External Specifications Diagramsp. 424

  +Basic Structure and Diagramsp. 425

  Assembly Cross Sectionp. 425

  Parts Listp. 426

  +TM40VD Maintenance Instructionsp. 428

  Precautionsp. 428

  +Tools List for Disassembly and Reassemblyp. 429

  Standard Toolsp. 429

  Machined Toolsp. 430

  +Disassembly Instructionsp. 432

  General Cautionsp. 432

  Disassembly procedurep. 432

  Disassembling Hydraulic motor Partp. 436

  +Reassemblyp. 443

  General Precautionsp. 443

  +Reassembly Procedurep. 443

  Reassemble the Hydraulic Motor Partp. 443

  Reassemble the Rear Flange Part (1)p. 447

  The Reduction Gear Assemblyp. 451

  Checking Facts After Assemblyp. 457

  Testingp. 458

  List of Sealsp. 460

  +Gear Pumpp. 461

  Safety Precautionsp. 465

  Applicable Modelsp. 465

  +Single Gear Pumpp. 467

  Disassemblyp. 467

  Reassemblyp. 469

  +Main Control Valvep. 473

  Safety Precautionsp. 477

  Applicable Modelsp. 477

  +General Descriptionp. 479

  +Theory of Operationp. 479

  When All Spools are in Neutralp. 479

  Single Operationp. 484

  Compound Operationp. 498

  Antidrift Valvep. 504

  Main Relief Valvep. 505

  Overload Relief Valvep. 506

  Low-pressure Relief Valvep. 508

  Parts Listp. 510

  Specificationsp. 515

  +Troubleshooting, Testing and Adjustmentp. 516

  +Troubleshootingp. 516

  Overall Control Valvep. 516

  Relief Valvep. 517

  Overall Oil Pressurep. 517

  +Adjustment of Valvesp. 517

  Main Relief Valvep. 517

  Overload Relief Valvep. 518

  +Disassemblyp. 519

  Caution in Disassemblyp. 519

  Disassembly of Main Spool Partp. 520

  Disassembly of Arm 1 Para-turn Spool Partp. 521

  Disassembly of Arm Regeneration Release Valve Partp. 521

  Disassembly of Load Check Valve Partp. 522

  Disassembly of Antidrift Valve Partp. 523

  Disassembly of Relief Valvep. 524

  Disassembly of Option Section Partp. 524

  Disassembly of Other Plugsp. 524

  Disassembly of Valve Housing Boltp. 525

  Disassembly of Main Relief Valvep. 526

  Disassembly of Overload Relief Valvep. 527

  Instruction of Disassembly and Assembly of Low-pressure Relief Valvep. 528

  +Cleaning and Inspection (Wear Limits and Tolerances)p. 529

  Cleaningp. 529

  Inspectionp. 529

  +Reassemblyp. 530

  +Caution on Assemblyp. 530

  Caution on Handling O-ringp. 530

  Caution on Handling Spoolp. 530

  Method of Painting the Adhesives (screw part and arm screw part of parts requiring the adhesiveness)p. 530

  +Sequence of Subassemblyp. 531

  Spool Assembly (Main Spool)p. 531

  Arm 1 Para-turn Spool Assemblyp. 531

  Antidrift Valve Assemblyp. 532

  Assembly Sequence of Main Body of the Control Valvep. 532

  Assembly of Relief Valvep. 533

  Assembly of Load Check Valvep. 533

  Assembly of Antidrift Valvep. 534

  Assembly of Option Section Partp. 534

  Assembly of Arm Regeneration Release Valvep. 534

  Assembly of Arm 1 Para-turn Spoolp. 535

  Assembly of Main Spoolp. 535

  Assembly of Other Plugsp. 536

  +Maintenance of Relief Valvesp. 537

  Reassembly of Main Relief Valvep. 537

  Reassembly of Overload Relief Valve (69, Total of 6 Places)p. 538

  Reassembly of Low-pressure Relief Valve (70, Total of 2 Places)p. 539

  Installationp. 540

  Start-up Proceduresp. 540

  +Axial Piston Pumpp. 541

  Safety Precautionsp. 545

  Applicable Modelsp. 545

  +Pump Maintenancep. 547

  Component Locationsp. 547

  Parts Listp. 549

  Toolsp. 550

  Tightening Torquep. 551

  Disassemblyp. 552

  Reassemblyp. 555

  +Pump Body Maintenance Standardsp. 558

  Change Standards of Worn Partsp. 558

  Fix Standards of Cylinder Block, Valve Plate, and Swash Plate (Shoe Plate)p. 559

  +PTO Serverp. 561

  Safety Precautionsp. 565

  Applicable Modelsp. 565

  Pump Maintenancep. 567

  Disassemblyp. 568

  Reassemblyp. 570

  Maintenance Standards of Pump Bodyp. 571

  +Remote Control Valve (Work Lever / Joystick)p. 573

  Safety Precautionsp. 577

  Applicable Modelsp. 577

  +General Descriptionp. 579

  +Theory of Operationp. 579

  Structurep. 579

  Functionp. 579

  Parts Listp. 580

  +Specificationsp. 582

  Performancep. 582

  Torquesp. 582

  Tools and Materialsp. 582

  Disassemblyp. 583

  Cleaning and Inspection (Wear Limits and Tolerances)p. 586

  Reassemblyp. 587

  Start-up Proceduresp. 593

  +Travel Control Valve (with Damper)p. 595

  Safety Precautionsp. 599

  Applicable Modelsp. 599

  +General Descriptionp. 601

  Theory of Operationp. 601

  Pressure Reducing Valvep. 602

  Operating Theory of Damper Mechanismp. 603

  +Causes of Faults and Measuresp. 605

  Parts Listp. 606

  Specificationp. 608

  Torquesp. 608

  Removalp. 609

  Disassemblyp. 610

  Cleaning and Inspection (Wear Limits and Tolerances)p. 612

  Reassemblyp. 613

  Installationp. 618

  Startup Proceduresp. 619

  +Solenoid Valve Assemblyp. 621

  Safety Precautionsp. 625

  Applicable Modelsp. 625

  +5-Solenoid Valvep. 626

  Parts Listp. 626

  +Functions of 5-Solenoid Valve Assembly Packagep. 627

  This solenoid valve assembly package have the following functions.p. 627

  Functions and Operations of Solenoid Valvesp. 627

  Detailed Functions and Operations of Solenoid Valvesp. 627

  Assembly Diagram and Tools Requiredp. 629

  Cautions During Disassembly and Reassemblyp. 630

  Solenoid Valve Diagramp. 631

  +Check Points and Solutions for Problemsp. 632

  Checking of Pilot Pressure for Defectsp. 632

  +2-Solenoid Valvep. 633

  Parts Listp. 633

  Assembly Diagram and Tools Reguiredp. 634

  Cautions During Disassembly and Reassemblyp. 635

  Solenoid Valve Diagramp. 636

  Troubleshooting Guidep. 636

  +Breaker EPPR Valve (Opt)p. 637

  Safety Precautionsp. 641

  Applicable Modelsp. 641

  +Structurep. 643

  Numbers and Names of Partsp. 643

  Functions and Operationp. 644

  Cautions for Operationp. 644

  +Maintenance Instructionsp. 645

  +Maintenancep. 645

  Bolt Tightening Torquep. 645

  Tools Used for Disassembly and Assemblyp. 645

  Disassemblyp. 646

  Assemblyp. 647

  +Hydraulic Schematic (DX225LC/ DX225LCA)p. 649

  Safety Precautionsp. 653

  Applicable Modelsp. 653

  DX225LC/DX225LCAp. 655

  +Electrical Systemp. 656

  +Electrical Systemp. 658

  Safety Precautionsp. 664

  Applicable Modelsp. 664

  +Introductionp. 666

  Electric Wire Colorp. 666

  Electrical Supply Systemp. 667

  +Engine Starting Circuitp. 669

  Start Operationp. 669

  +After Startp. 671

  Operation of the Start Circuit (2)  Immediately After Startp. 672

  Engine Preheating Systemp. 673

  Engine Stopp. 674

  Charging Systemp. 675

  +Monitoring Systemp. 676

  Instrument Panelp. 677

  Monitoring System Schematicp. 679

  +Operationp. 681

  Instrumentsp. 681

  +Warning and Indicator Lightsp. 683

  Indication of Warning Lightsp. 683

  Indication of Multifunction Gauge and Letter Information Areap. 684

  Initial Operationp. 685

  +Mode Selector Switchp. 686

  Power Mode Switchp. 686

  Auto Idle Switchp. 686

  +Graphic Information Area Displayp. 687

  Overviewp. 687

  Main Menus for the Graphic Display Areap. 688

  Menu Selector Buttonsp. 688

  +Main Menup. 689

  Languagep. 689

  Set Clockp. 690

  +Filter/Oil Infop. 690

  Menu Display Order and Icon Explanationp. 691

  Adjust Displayp. 691

  Set Passwordp. 692

  +Special Menup. 693

  +Entering/Accessing and Exiting/Escaping Menusp. 693

  Entering/Accessing Menusp. 693

  Exiting/Escaping Menusp. 694

  +Special Menu Selectionsp. 694

  Information of Machine Statusp. 694

  Failure Informationp. 698

  Information of Machine Operationp. 703

  Machine Operation Info Screenp. 706

  +Electronic Hydraulic Control System (eEPOS)p. 707

  Control System Schematicp. 707

  +Power Mode Controlp. 709

  +Operationp. 711

  1. Power Modep. 711

  2. Standard Modep. 712

  3 Operation in case of failure in the control system (Aux mode operationp. 712

  Power Mode Control  Circuit Diagramp. 713

  Work Mode Controlp. 714

  Work Mode Control  Circuit Diagramp. 715

  Engine Control Systemp. 716

  Engine Control Dialp. 717

  Engine Control Motorp. 718

  Engine Control Circuit Diagramp. 719

  Automatic Deceleration Control (Auto Idle Control)p. 720

  Engine Overheat Protection Systemp. 721

  +Power Boost Modep. 722

  Operationp. 722

  Power Boost Control  Circuit Diagramp. 723

  +Automatic Travel Speed Controlp. 724

  Automatic Travel Speed Control  Circuit Diagramp. 725

  Adjust Engine Speedp. 729

  Engine Throttle controllerp. 730

  +Selfdiagnostic Functionp. 731

  eEPOS Controllerp. 731

  +Air Conditioner Systemp. 732

  Outlinep. 732

  +Internal and External Filtersp. 733

  How to Check Internal Air Filterp. 733

  How to Check External Air Filterp. 733

  AirConditioning System Layoutp. 735

  Air Conditioner/heater Circuit Diagramp. 736

  +Air Conditioner/heater Unitp. 737

  Air Flow Diagramp. 737

  Door Open by Vent Modesp. 738

  Main Componentsp. 738

  Actuator  Wind Direction Controlp. 739

  Actuator  Temperature Controlp. 739

  Actuator  Internal/external Air Exchangep. 740

  Air Flow Control Modulep. 740

  Ambient Air Temperature Sensorp. 742

  Sun Sensorp. 743

  +Control Panelp. 743

  Appearance and Terminal Arrangementp. 743

  Terminal Termsp. 744

  Control Logicp. 745

  Self Diagnosisp. 749

  Ambient Temperature Displayp. 750

  Compressorp. 751

  Receiver Dryerp. 751

  +Wiper Systemp. 752

  Wiper Circuitp. 752

  +Wiper operationp. 753

  Continuous operationp. 753

  Intermittent operationp. 753

  +Lighting Systemp. 755

  Lighting System Circuit Diagramp. 755

  Kind of Lightp. 756

  Operationp. 756

  +Overload Warning Devicep. 757

  Overload Warning Device Circuit Diagramp. 757

  +Audio Controllerp. 758

  +Audio Controller Circuit Diagramp. 758

  Operations Via Audio Control Panelp. 758

  +Electrical Schematic (DX225LCA)p. 760

  Safety Precautionsp. 764

  Applicable Modelsp. 764

  DX225LCAp. 766

  +Attachmentsp. 767

  +Boom and Armp. 769

  Safety Precautionsp. 773

  Applicable Modelsp. 773

  Front Attachment Pin Specificationsp. 775

  +Front Attachment – Removal and Installationp. 777

  Arm Removal Procedurep. 777

  Boom Removal Procedurep. 779

  +Installationp. 780

  Arm Installation Procedurep. 780

  Boom Installation Procedurep. 780

  Start-up Proceduresp. 780

  +Bucketp. 781

  Safety Precautionsp. 785

  Applicable Modelsp. 785

  Bucket Tooth Inspection and Replacementp. 787

  Bucket O-ring Replacementp. 788

  +Bucket Attachment, Removal and Reversalp. 790

  Detaching the Bucketp. 790

  Attaching the Bucketp. 790

  Reversing the Bucketp. 791

• Electrical System
  • Electrical System
  • Electrical Schematic (DX225LCA)
• Attachments
  • Boom and Arm
  • Bucket

Taken together, this Doosan DX225LCA Shop Manual gives a technician everything needed to move from diagnosis to teardown to reassembly on any major system of the machine, from the swing bearing and travel motors down to the boom and arm cylinders, without having to cross-reference a separate parts book or electrical supplement.

Specifications and Reference Data

The Specification for DX225LCA section alone is worth the manual: it lists general dimensions and working ranges for every boom/arm/bucket combination Doosan offered on this model (5.2 m and 5.7 m booms with 2.0 m, 2.4 m, 2.9 m and 3.5 m arms), shipping and operating weights, major component weights, digging forces at power boost, fuel and hydraulic tank capacities, ground pressure ratings for each shoe width, and the DB58TIS engine’s rated power, torque and fuel consumption curves per the DIN 6270 standard. The Standard Torques section adds metric and U.S. fastener torque tables, hose clamp and split-flange torque values, and torque wrench extension guidance that applies across the whole machine.

Hydraulics and Electrical Coverage

Because the DX225LCA is a hydraulic excavator, the manual devotes its largest section to hydraulics: troubleshooting and adjustment procedures for the whole circuit, plus dedicated coverage of the accumulator, center joint, cylinders, swing motor, travel motor, gear pump, main control valve, axial piston pump, PTO server, remote and travel control valves, solenoid valve assembly, and the optional breaker EPPR valve, backed by the full hydraulic schematic for the DX225LC/DX225LCA. The Electrical System section covers the machine’s wiring logic alongside the complete electrical schematic for the DX225LCA, so electrical faults can be traced circuit by circuit rather than guessed at.

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Why Technicians Choose This Doosan DX225LCA Shop Manual

With this Doosan DX225LCA Shop Manual you can diagnose hydraulic pressure and flow problems, rebuild or replace the swing motor, travel motor, main control valve or axial piston pump, service the swing bearing and reduction gear, correctly torque structural and hydraulic fasteners, trace electrical faults using the factory schematic, and work through counterweight, fuel tank, cabin, track assembly, boom, arm and bucket service using Doosan’s own procedures and specifications rather than guesswork. Using the correct torque values, clearances and hydraulic settings from this Shop Manual protects the machine from repeat failures and keeps repairs within the tolerances Doosan engineered for the DX225LCA. This is an instant PDF download – there is no physical item shipped. Once payment is confirmed you can save the DX225LCA Shop Manual to a laptop, tablet or phone, print any section you need in the shop, and reference it on any device without waiting on the mail.