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DOOSAN DX225MH 3 EXCAVATOR SHOP MANUAL 950106-01407E – PDF DOWNLOAD
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DOOSAN DX225MH 3 EXCAVATOR SHOP MANUAL 950106-01407E – PDF DOWNLOAD
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Description
DOOSAN DX225MH 3 EXCAVATOR SHOP MANUAL 950106-01407E – PDF DOWNLOAD
DESCRIPTION:
DOOSAN DX225MH 3 EXCAVATOR SHOP MANUAL 950106-01407E – PDF DOWNLOAD
IMPORTANT
When disconnecting or connecting connectors between ECU and engine, or connector between ECU and the machine, always disconnect the battery to prevent damage to ECU. If you do not follow this procedure, the ECU will be damaged and/or the engine will not operate properly
When performing welding repairs, perform welding in a properly equipped place. Repairs must be performed by a qualified welder. Welding operations, can create potential hazards, including generation of gas, fire, or electric shock. Never let an unqualified welder do welding. A qualified welder must do the following:
• To prevent battery explosion, turn battery disconnect
switch to “OFF” position.
• Disconnect the connector between ECU and machine, and
the connector between ECU and engine.
• To prevent generation of gas, remove paint from location
of the weld.
• If hydraulic equipment, piping or component ports close to
them are heated, a flammable gas or mist could result in
an explosion or fire. To prevent this, protect and insulate
components from excessive heat.
• Do not weld on pipes or on tubes that contain flammable
fluids. Do not flame cut pipes or tubes that contain
flammable fluids. Before welding on pipes or tubes, or
before flaming cut pipes or tubes, clean them thoroughly
with a nonflammable solvent. Make sure pressure inside
pipes or tubes does not cause a rupture of the component
parts.
• If heat is applied directly to rubber hoses or piping under
pressure, they may suddenly break, so cover and insulate
them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and make sure a fire
extinguisher is available.
TABLE OF CONTENTS:
DOOSAN DX225MH 3 EXCAVATOR SHOP MANUAL 950106-01407E – PDF DOWNLOAD
sm-950106-01407 E_DX225MH-3_2014-02-26............................................................... 7 Safety........................................................................................... 9 Material Handler Maintenance Safety SP002322NA............................................... 11 Safety Instructions...................................................................... 15 Applicable Models........................................................................ 15 Safety Messages.......................................................................... 16 Signal Words......................................................................... 16 Safety Decals............................................................................ 17 General.................................................................................. 17 Safe Operation is Operator's Responsibility.......................................... 17 Know Your Machine.................................................................... 17 Proper Work Tools and Attachments.................................................... 18 Pressurized Fluids................................................................... 18 Flying or Falling Objects............................................................ 19 Personal Protective Equipment (PPE).................................................. 20 Correction of Machine Problems....................................................... 20 Crushing and Cutting................................................................. 20 Hot Coolant and Oils - Burn Prevention............................................... 21 Fire and Explosion Prevention........................................................ 22 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit).......................... 25 Electrical System and Electrical Shock............................................... 26 Transportation........................................................................... 30 Obey State and Local Over-the-Road Regulations....................................... 30 Loading and Unloading................................................................ 30 Transporting Machine................................................................. 31 Operation................................................................................ 32 Before Engine Starting............................................................... 32 Work Site............................................................................ 33 Mounting/Dismounting................................................................. 34 Cleaning............................................................................. 36 Operator Station..................................................................... 36 Seat Belt............................................................................ 37 Visibility Information............................................................... 38 Boost Starting or Charging Engine Batteries.......................................... 39 Swinging or Traveling................................................................ 41 Lifting.............................................................................. 43 Towing............................................................................... 44 Attachment........................................................................... 45 Equipment Lowering with Engine Stopped............................................... 45 Lowering Elevating Cab with Engine Stopped........................................... 46 Engine Stop.......................................................................... 46 Parking Machine...................................................................... 47 Preservation/Storing Machine......................................................... 48 Maintenance.............................................................................. 50 Cleaning............................................................................. 54 Proper Tools and Clothing............................................................ 54 Disassembling Precautions............................................................ 54 Use of Lighting...................................................................... 55 Fire and Explosion Prevention........................................................ 55 Burn Prevention...................................................................... 56 Rubber That Contains Fluorides....................................................... 57 Rubber and Plastics.................................................................. 58 Welding Repairs...................................................................... 59 Warning for Counterweight and Front Attachment Removal............................... 60 Lock Inspection Covers............................................................... 61 Working on Machine................................................................... 61 Accumulator.......................................................................... 62 Compressed Air....................................................................... 62 Track Tension Adjustments............................................................ 63 Supports and Blocking for Work Equipment............................................. 63 High-pressure Lines, Tubes and Hoses................................................. 64 Battery.............................................................................. 65 Environment and Circumstances............................................................ 67 Work Site Areas Requiring Extra Caution.............................................. 67 High-voltage Cables.................................................................. 68 Working in Water..................................................................... 69 Working in Contaminated Environment.................................................. 69 Operation in Extreme Conditions...................................................... 70 Exhaust Ventilation.................................................................. 74 Asbestos Information................................................................. 74 Silica Dust Information.............................................................. 75 Disposal of Hazardous Materials...................................................... 75 Specifications................................................................................... 77 Specifications SP002491NA.................................................................... 79 Safety Instructions...................................................................... 83 Applicable Models........................................................................ 83 General Description...................................................................... 85 Component Locations...................................................................... 86 Tilting Riser........................................................................ 88 Elevating Cab........................................................................ 89 General Dimensions....................................................................... 90 Tilting Riser With One - Piece Boom.................................................. 90 Elevating Cab With One - Piece Boom.................................................. 91 Working Range............................................................................ 92 One - Piece Boom..................................................................... 92 General Specifications................................................................... 93 Performance Tests........................................................................ 96 Material Handler Performance Measurements................................................ 97 Test Conditions...................................................................... 97 Travel Speed and Travel Motor Balance (Steering Deviation) Tests..................... 97 Swing Speed and Deceleration Force Test.............................................. 99 Cylinder Performance Tests...........................................................101 General Maintenance..............................................................................103 General Maintenance Instructions SP002454NA..................................................105 Safety Instructions......................................................................109 Applicable Models........................................................................109 Welding Precautions and Instructions.....................................................110 Hydraulic System - General Precautions...................................................111 Maintenance Service and Repair Procedure.................................................113 General Precautions..................................................................113 Hydraulic System Cleanliness and Oil Leaks...............................................114 Maintenance Precautions for Hydraulic System Service.................................114 Oil Leakage Precautions..............................................................115 Cleaning and Inspection..................................................................116 General Instructions.................................................................116 Bearing Inspection...................................................................117 Standard Torques.............................................................................125 Safety Instructions......................................................................129 Applicable Models........................................................................129 Torque Values for Standard Metric Fasteners..............................................130 Torque Values for Standard U.S. Fasteners................................................131 Type 8 Phosphate Coated Hardware.........................................................133 Torque Values for Hose Clamps............................................................134 ORFS Swivel Nut Recommended Torque.......................................................134 Torque Values for Split Flanges..........................................................135 Torque Wrench Extension Tools............................................................136 Torque Multiplication................................................................136 Other Uses for Torque Wrench Extension Tools.........................................137 Tightening Torque Specifications (Metric)............................................138 Upper Structure..................................................................................141 Cabin SP002324NA.............................................................................143 Safety Instructions......................................................................147 Applicable Models........................................................................147 Cabin Identification.....................................................................148 General Instructions for Cabin.......................................................148 Counterweight SP002492NA.....................................................................157 Safety Instructions......................................................................161 Applicable Models........................................................................161 General..................................................................................162 Warning for Counterweight and Front Attachment Removal...............................162 Installation.............................................................................166 Fuel Tank SP002493NA.........................................................................169 Safety Instructions......................................................................173 Applicable Models........................................................................173 General Description...................................................................... 0 Specifications.......................................................................175 Start-up Procedures......................................................................183 Fuel Transfer Pump (Option) SP002534NA.......................................................185 Safety Instructions......................................................................189 Applicable Models........................................................................189 Troubleshooting..........................................................................192 Replacement of Rotor and Vane............................................................192 Swing Bearing SP002329NA.....................................................................195 Safety Instructions......................................................................199 Applicable Models........................................................................199 Swing Bearing Maintenance................................................................200 Operating Recommendation.............................................................200 Measuring Swing Bearing Axial Play...................................................200 Measuring Bearing Lateral Play.......................................................200 Swing Bearing Basic Operation........................................................201 Disassembly..........................................................................201 Assembly.............................................................................203 Lower Structure and Chassis......................................................................205 Track Assembly SP002494NA....................................................................207 Safety Instructions......................................................................211 Applicable Models........................................................................211 General Description......................................................................212 Track Tension............................................................................213 Cleaning and Inspection (Wear Limits and Tolerances).....................................215 Track Shoe...........................................................................216 Lower Roller.........................................................................218 Upper Roller.........................................................................219 Front Idler..........................................................................220 Track Shoes and Links....................................................................221 Track Removal........................................................................221 Track Installation...................................................................222 Front Idler Roller.......................................................................223 Parts List...........................................................................223 Front Idler Roller Disassembly.......................................................224 Front Idler Roller Reassembly........................................................226 Lower Roller.............................................................................228 Parts List...........................................................................228 Lower Roller Removal.................................................................229 Lower Roller Disassembly.............................................................229 Lower Roller Reassembly..............................................................230 Lower Roller Installation............................................................231 Upper Roller.............................................................................232 Parts List...........................................................................232 Upper Roller Removal.................................................................233 Upper Roller Disassembly.............................................................233 Upper Roller Reassembly..............................................................235 Track Spring and Track Adjusting Cylinder................................................236 Parts List...........................................................................236 Engine and Drivetrain............................................................................239 Engine Coolant Heater (Option) SP002328NA....................................................241 Safety Instructions......................................................................245 Applicable Models........................................................................245 Disassembly and Assembly.................................................................246 Changing the Circulating Pump........................................................246 Changing the Temperature Limiter.....................................................248 Changing the Temperature Sensor......................................................249 Changing the Combustion Air Fan......................................................251 Changing the Burner, Flame Monitor and Glow Plug.....................................253 Changing the Burner Head.............................................................255 Changing the Heat Exchanger..........................................................257 Drive Coupling (Main Pump)...................................................................259 Safety Instructions......................................................................263 Applicable Models........................................................................263 Drive Coupling...........................................................................264 Special Tools............................................................................265 Installation of Drive Coupling...........................................................266 Installation Procedure...............................................................268 Hydraulics.......................................................................................269 Hydraulic System Troubleshooting, Testing and Adjustment SP002535NA..........................271 Safety Instructions......................................................................275 Applicable Models........................................................................275 Hydraulic System - General Notes.........................................................276 Hydraulic Schematic......................................................................277 General Notes........................................................................277 Operation of Working Components..........................................................279 Boom Operating Circuit...............................................................279 Boom Up Circuit......................................................................279 Boom Down Circuit....................................................................279 Arm Operating Circuit................................................................280 Arm Crowd Circuit....................................................................280 Arm Dump Circuit.....................................................................280 Grapple Operating Circuit............................................................281 Grapple Close Circuit................................................................281 Grapple Open Circuit.................................................................281 Swing Operating Circuit..............................................................281 Right Swing Operating Circuit........................................................282 Left Swing Operating Circuit.........................................................282 Swing Relief Valve and Makeup Valve..................................................282 Travel Operating Circuit.............................................................282 Forward Travel Circuit...............................................................283 Reverse Travel Circuit...............................................................283 Procedural Troubleshooting Baseline Recommendations......................................284 Initial Checks and Tests to Establish Operating Condition of the Material Handler....284 Pilot Pressure...........................................................................286 Adjustment and Testing...............................................................286 Power Mode Valve.........................................................................287 Current Signal and Hydraulic Pressure Adjustments....................................287 Pressure Up Valve........................................................................288 Checks and Adjustments...............................................................288 Pump Input Power Control.................................................................290 Pump Regulator Adjustment............................................................290 Flow Meter and Flow Meter Kit Installation and Testing...................................293 Swing System Troubleshooting.............................................................295 Precautions/Initial Checks...........................................................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 Accumulator SP002455NA.......................................................................305 Safety Instructions......................................................................309 Applicable Models........................................................................309 General Description...................................................................... 0 Specifications.......................................................................312 Center Joint (Swivel) SP002456NA.............................................................313 Safety Instructions......................................................................317 Applicable Models........................................................................317 General Description......................................................................319 Parts List...........................................................................320 Troubleshooting, Testing and Adjustment..................................................321 Inspection...........................................................................321 Testing..............................................................................321 Disassembly..............................................................................322 Reassembly...............................................................................325 Cylinders SP002497NA.........................................................................327 Safety Instructions......................................................................331 Applicable Models........................................................................331 General Description......................................................................332 Theory of Operation..................................................................332 Parts List...........................................................................334 Disassembly..............................................................................357 Reassembly...............................................................................362 Swing Device SP002498NA......................................................................367 Safety Instructions......................................................................371 Applicable Models........................................................................371 Indication of Type.......................................................................372 Specifications...........................................................................373 Structure and Principle of Operation.....................................................374 Structure............................................................................374 Principles of Operation..............................................................379 Valve Casing.........................................................................380 Brake Part...........................................................................383 Cautions for Operation...................................................................384 Inspection...........................................................................384 Direction of Rotation................................................................384 External Load at the End of Shaft....................................................385 Hydraulic Oil and Temperature Range..................................................385 Filter...............................................................................386 Installation and Piping..............................................................386 Oil Filling and Air Breather.........................................................387 Instructions before Starting to Operate..............................................387 Troubleshooting..........................................................................388 General Pre-caustions................................................................388 Examination of Hydraulic Motor.......................................................388 Troubleshooting......................................................................389 Disassembly and Reassembly...............................................................392 Disassemble Swing Motor..............................................................394 Reassemble Swing Motor...............................................................398 Disassemble the Reduction Gear.......................................................403 Reassemble the Reduction Gear........................................................407 Maintenance Instructions.............................................................415 Travel Device................................................................................417 Safety Instructions......................................................................421 Applicable Models........................................................................421 TM40VD Operation Manual..................................................................422 Specifications...........................................................................422 Indication of Type.......................................................................423 Basic Structure and Diagram..........................................................424 Basic Structure of TM Motor......................................................424 Operation Principles.................................................................425 Reducer..........................................................................425 Hydraulic Motor (Brake Valve, Parking Brake, High and Low 2-Speed Shifting)......426 Cautions for Operation...............................................................432 Installation Method (Refer to the External Specifications Diagrams.).............432 Piping...........................................................................432 Hydraulic Oil....................................................................433 Lubricating Oil..................................................................434 Maintenance......................................................................435 Troubleshooting..................................................................436 External Specifications Diagrams.....................................................438 Basic Structure and Diagrams.........................................................439 Assembly Cross-Section...........................................................439 TM40VD Maintenance Instructions..........................................................442 Precautions..........................................................................442 Tools List for Disassembly and Reassembly............................................443 Standard Tools...................................................................443 Machined Tools...................................................................444 Disassembly Instructions.............................................................446 General Cautions.................................................................446 Disassembly procedure............................................................446 Reassembly...........................................................................457 General Precautions..............................................................457 Reassembly Procedure.............................................................457 Checking Facts After Assembly....................................................471 Testing..............................................................................472 List of Seals........................................................................474 Main Pump....................................................................................475 Safety Instructions......................................................................479 Applicable Models........................................................................479 Pump Maintenance......................................................................... 0 Parts List...........................................................................482 Tools................................................................................484 Tightening Torque....................................................................485 Disassembly..............................................................................486 Reassembly...............................................................................489 Pump Body Maintenance Standards..........................................................492 Change Standards of Worn Parts.......................................................492 Fix Standards of Cylinder Block, Valve Plate, and Swash Plate (Shoe Plate)...........493 PTO Server...................................................................................495 Safety Instructions......................................................................499 Applicable Models........................................................................499 Pump Maintenance.........................................................................500 Disassembly..............................................................................501 Reassembly...............................................................................503 Maintenance Standards of Pump Body.......................................................504 Gear Pump....................................................................................507 Safety Instructions......................................................................511 Applicable Models........................................................................511 Single Gear Pump.........................................................................512 Disassembly..........................................................................512 Reassembly...........................................................................514 Main Control Valve SP002403NA................................................................519 Safety Instructions......................................................................523 Applicable Models........................................................................523 General Description......................................................................524 Theory of Operation..................................................................524 Parts List...........................................................................556 Specifications.......................................................................561 Troubleshooting, Testing and Adjustment..................................................562 Troubleshooting......................................................................562 Adjustment of Valves.................................................................563 Removal..................................................................................565 Disassembly..............................................................................566 Cleaning and Inspection (Wear Limits and Tolerances).....................................575 Cleaning.............................................................................575 Inspection...........................................................................575 Reassembly...............................................................................576 Caution on Assembly..................................................................576 Sequence of Subassembly..............................................................577 Maintenance of Relief Valves.........................................................583 Installation.............................................................................586 Start-up Procedures......................................................................587 Remote Control Valve (Work Lever / Joystick) SP002395NA......................................589 Safety Instructions......................................................................593 Applicable Models........................................................................593 General Description......................................................................595 Theory of Operation..................................................................595 Parts List...........................................................................596 Specifications.......................................................................598 Torques..............................................................................598 Tools and Materials......................................................................598 Disassembly..............................................................................599 Reassembly...............................................................................602 Start-up Procedures......................................................................610 Travel Control Valve (with Damper) SP002381NA................................................611 Safety Instructions......................................................................615 Applicable Models........................................................................615 General Description......................................................................616 Theory of Operation..................................................................616 Pressure Reducing Valve..............................................................617 Operating Theory of Damper Mechanism.................................................618 Causes of Faults and Measures............................................................619 Parts List...........................................................................620 Specification........................................................................622 Torques..............................................................................622 Disassembly..............................................................................626 Cleaning and Inspection (Wear Limits and Tolerances).....................................628 Reassembly...............................................................................629 Installation.............................................................................634 Start-up Procedures......................................................................637 Solenoid Valve Assembly SP002406NA...........................................................639 Safety Instructions......................................................................643 Applicable Models........................................................................643 5-Solenoid Valve.........................................................................644 Parts List...........................................................................644 Functions of 5-Solenoid Valve Assembly...............................................645 Assembly Diagram and Tools Required..................................................646 Cautions During Disassembly and Reassembly...........................................647 Solenoid Valve Diagram...............................................................648 Check Points and Solutions for Problems..............................................649 Hydraulic Schematic SP002507NA...............................................................651 Safety Instructions......................................................................655 Applicable Models........................................................................655 DX225LC-3/DX225MH-3......................................................................657 Electrical System................................................................................659 Electrical System SP002337NA.................................................................661 Safety Instructions......................................................................667 Applicable Models........................................................................667 Introduction.............................................................................668 Electrical Supply System.................................................................670 Engine Starting Circuit..................................................................672 Start Operation......................................................................672 After Start..........................................................................674 Engine Preheating System.................................................................676 Engine Stop..............................................................................678 Monitoring System........................................................................681 Instrument Panel.....................................................................682 Functional Check.....................................................................682 Monitoring System Schematic..........................................................684 Operation................................................................................686 Instruments..........................................................................686 Warning and Indicator Lights............................................................. 0 Indication of Multifunction Gauge....................................................690 Initial Operation........................................................................691 Graphic Information Area Display.........................................................692 Overview.............................................................................692 Main Menus for the Graphic Display Area..............................................692 Menu Selector Buttons................................................................692 Special Menu.............................................................................725 Entering/Accessing and Exiting/Escaping Menus........................................725 Special Menu Selections..............................................................726 Electronic Hydraulic Control System (e-EPOS).............................................752 Control System Schematic.............................................................752 Power Plus Mode Control..................................................................754 Operation............................................................................756 Power Mode Control - Circuit Diagram.....................................................758 Engine Control System....................................................................760 Engine Control Dial......................................................................761 Engine Control Circuit Diagram...........................................................762 Automatic Deceleration Control (Auto Idle Control).......................................764 Engine Overheat Protection System........................................................766 Power Boost Mode.........................................................................768 Operation............................................................................768 Power Boost Control - Circuit Diagram................................................770 Automatic Travel Speed Control...........................................................772 Self-diagnostic Function.................................................................775 e-EPOS Controller....................................................................775 Air Conditioner System...................................................................777 Outline..............................................................................777 Internal and External Filters........................................................778 Air-Conditioning System Layout.......................................................780 Air Conditioner/heater Circuit Diagram...............................................781 Air Conditioner/heater Unit..........................................................782 Ambient Air Temperature Sensor.......................................................787 Compressor...........................................................................796 Receiver Dryer.......................................................................796 Troubleshooting..........................................................................797 Weight of R134a Gas Used In Machines.....................................................799 Refrigerant System Repairs...............................................................800 Refrigerant Safe Handling Procedures.................................................800 Repair and Replacement Procedure.....................................................801 Refrigerant Recovery.................................................................803 Vacuuming Refrigerant System.........................................................803 Leakage Check........................................................................805 Refrigerant Charging.................................................................805 Inspecting System For Leakage........................................................807 Wiper System.............................................................................808 Wiper Circuit........................................................................808 Wiper operation......................................................................809 Lighting System.......................................................................... 0 Kind of Light........................................................................813 Operation............................................................................813 Overload Warning Device..................................................................814 Overload Warning Device Circuit Diagram..............................................814 Electrical Schematic SP002508NA..............................................................817 Safety Instructions......................................................................821 Applicable Models........................................................................821 DX140LC-3/DX180LC-3/DX225LC-3/DX225MH-3/DX255LC-3........................................823 Attachments......................................................................................825 Boom and Arm SP002505NA......................................................................827 Safety Instructions......................................................................831 Applicable Models........................................................................831 Front Attachment Pin Specifications......................................................832 DX225MH-3............................................................................833 Front Attachment - Removal and Installation..............................................834 Arm Removal Procedure................................................................834 Boom Removal Procedure...............................................................841 Installation.............................................................................847 Boom Installation Procedure..........................................................847 Arm Installation Procedure...........................................................854 Start-up Procedures......................................................................859 Attachment SP002506NA........................................................................861 Safety Instructions......................................................................865 Applicable Models........................................................................865 Attachments..............................................................................866 Installation and Removal.............................................................866
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