Doosan DX225LC-3 Install guide

Shop
Manual
Doosan Infracore
Construction Equipment
DX225LC-3
Serial Number 1001 and Up
Serial Number 50001 and Up (Europe Only)
950106-00364E
March 2012
EXCAVATOR

WARNING
CALIFORNIA PROPOSITION 65
WARNING
Diesel engine exhaust and some of its constituents are
known to the state of California to cause cancer, birth
defects and other reproductive harm.
WARNING
CALIFORNIA PROPOSITION 65
WARNING
Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the State
of California to cause cancer and birth defects or other
reproductive harm. WASH HANDS AFTER HANDLING.
05-2010

Copyright Doosan 2011Operation and Maintenance Manual
Shop Manual
DX225LC-3 EXCAVATOR
Serial Number 1001 and Up
Serial Number 50001 and Up (Europe Only)
950106-00364E
March 2012
Copyright DOOSAN 2012
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

Product Label
Instructions
Trim Out The Label Along
The LinesAnd Insert Into
Pocket On The Binder Spine
DX225LC-3 Serial Number 1001 and Up Serial Number 50001 and Up (Europe Only) Pub.No. 950106-00364E
Pub. No. 950106-00364E

Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Maintenance Safety................................................... SP002322
Specifications
Specifications for DX225LC-3............................................................... SP002491
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Upper Structure
Cabin .................................................................................................... SP002324
Counterweight.......................................................................................SP002492
Fuel Tank..............................................................................................SP002493
Fuel Transfer Pump (Option)................................................................ SP002534
Swing Bearing....................................................................................... SP002329
Lower Structure and Chassis
Track Assembly.................................................................................... SP002494
Engine and Drivetrain
Engine Coolant Heater (Option) ........................................................... SP002328
Drive Coupling (Main Pump)................................................................. SP002495
Hydraulics
Hydraulic System Troubleshooting, Testing and Adjustment............... SP002535
Accumulator.......................................................................................... SP002455
Center Joint (Swivel)............................................................................. SP002456
Cylinders............................................................................................... SP002497

Table of Contents
Page II
Swing Device........................................................................................ SP002498
Travel Device........................................................................................ SP002499
Main Pump............................................................................................ SP002502
PTO Server........................................................................................... SP002503
Gear Pump ........................................................................................... SP002500
Main Control Valve ............................................................................... SP002403
Remote Control Valve (Work Lever / Joystick)..................................... SP002395
Travel Control Valve (with Damper)...................................................... SP002381
Solenoid Valve Assembly..................................................................... SP002406
Breaker EPPR Valve (Option) .............................................................. SP002458
Dozer Valve.......................................................................................... SP002529
Hydraulic Schematic (DX225LC-3)....................................................... SP002507
Electrical System
Electrical System.................................................................................. SP002337
Electrical Schematic ............................................................................. SP002508
Attachments
Boom and Arm...................................................................................... SP002505
Bucket................................................................................................... SP002506

1Safety

SP002322
Page 1
Track Excavator Maintenance Safety
SP002322
TRACK EXCAVATOR MAINTENANCE SAFETY
SP002322
Track Excavator
Maintenance
Safety
Edition 2

SP002322
Track Excavator Maintenance Safety
Page 2
MEMO

SP002322
Page 3
Track Excavator Maintenance Safety
Table of Contents
Track Excavator Maintenance Safety
Safety Instructions................................................5
Applicable Models ................................................5
Safety Messages..................................................6
Safety Decals .......................................................7
General.................................................................7
Transportation ....................................................20
Operation............................................................22
Maintenance.......................................................39
Environment and Circumstances........................56

SP002322
Track Excavator Maintenance Safety
Page 4
MEMO

SP002322
Page 5
Track Excavator Maintenance Safety
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
MODEL SERIAL NUMBER RANGE
DX140LC-3 1001 and Up, 50001 and Up
DX180LC-3 1001 and Up, 50001 and Up
DX225LC-3 1001 and Up, 50001 and Up
DX255LC-3 1001 and Up, 50001 and Up
DX300LC-3 1001 and Up, 50001 and Up
DX340LC-3 1001 and Up, 10001 and Up
DX350LC-3 1001 and Up, 10001 and Up
DX380LC-3 10001 and Up
DX420LC-3 10001 and Up
DX490LC-3 10001 and Up
DX530LC-3 10001 and Up

SP002322Track Excavator Maintenance Safety
Page 6
SAFETY MESSAGES
Safety messages and safety decals included in this manual and
on the machine provide instructions how to operate, service and
maintain the machine. Safety messages and safety decals
indicate potential hazards and describe safety precautions
required to avoid hazards. Operator and maintenance personnel
should read and understand these safety messages and decals
before beginning operation or maintenance.
Signal Words
The signal words "DANGER", "WARNING", "CAUTION" are
used throughout safety messages and safety decals in this
manual or on the machine. They indicate an existence of, and
the relative seriousness of, a hazard. All three indicate that a
safety risk is involved. Observe the precautions indicated
whenever a Safety Alert Symbol is present, no matter which
signal word appears next to it.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety
Instructions.
This is a Safety Alert Symbol. Wherever it appears in this
manual or on safety decals on the machine, you should be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
DANGER
DANGER - This signal word is used on safety messages and
safety labels and indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety messages and
safety labels and indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION - This signal word is used on safety messages and
safety labels and indicates a potentially hazardous situation
which, if not avoided, could result in minor or moderate injury.

SP002322
Page 7
Track Excavator Maintenance Safety
SAFETY DECALS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
GENERAL
Safe Operation is Operator's
Responsibility
Only trained and authorized personnel should operate and
maintain the machine.
Follow all safety rules, regulations and instructions when
operating or performing maintenance on machine.
• Do not operate machine if you are under the influence of
drugs or alcohol. An operator who is taking prescription
drugs must get medical advice to determine if he or she
can safely operate a machine.
• When working with other personnel on a worksite, be sure
that all personnel know nature of work and understand all
hand signals that are to be used.
• Be sure that all guards and shields are installed in their
proper location. Have guards and shields repaired or
replaced immediately if damaged.
• Be sure that you understand the use and maintenance of
all safety features such as safety lock lever and seat belt.
Use them properly.
• Never remove, modify or disable any safety features.
Always keep them in good operating condition.
• Always check for and know the location of underground
and overhead utility lines before excavating.
• Failure to use and maintain safety features according to
instructions in this manual, Safety Manual and Shop
Manual can result in death or serious injury.
Know Your Machine
Know how to operate your machine. Know the purpose of all
controls, gauges, signals, indicators and monitor displays. Know
the rated load capacity, speed range, braking and steering
characteristics, turning radius and operating clearances. Keep in
mind that rain, snow, ice, loose gravel, soft ground, slopes etc.,
can change operating capabilities of your machine.

SP002322Track Excavator Maintenance Safety
Page 8
Proper Work Tools and Attachments
Only use work tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When installing and
using optional attachments, read instruction manual for
attachment, and general information related to attachments in
this manual. Because DOOSAN cannot anticipate, identify or
test all attachments that owners may want to install on their
machines, contact DOOSAN for written authorization and
approval of attachments, and their compatibility with optional
kits.
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or combination of work
equipment, there is a potential that work equipment could
interfere with the cabin or other parts of machine. Before using
unfamiliar work equipment, check if there is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary hydraulic kits
for attachments installation. If you are in doubt about
compatibility of a particular attachment with a machine, consult
your DOOSAN distributor.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure
to do so can result in death or serious injury.
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and should be
relieved before maintenance is started.
FG018457
Figure 1

SP002322
Page 9
Track Excavator Maintenance Safety
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose to whip or oil
to spray. Fluid penetration can result in death or serious injury. If
fluid enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Obey all local laws and regulations for disposal of liquids.
To prevent hot coolant from spraying out, stop engine and wait
for coolant to cool. Using gloves, slowly loosen cap to relieve
pressure.
Flying or Falling Objects
On work sites where there is a potential hazard that flying or
falling objects can hit operator's cabin, select and use a guard to
match operating conditions for additional operator protection.
Working in mines, tunnels, deep pits, and loose or wet surfaces,
could produce hazard of falling rocks or flying objects. Additional
protection for operator's cabin could be required such as an
Operator Protection Guard (OPG) or window guards. Contact
your DOOSAN distributor for information on available protective
guards.
To prevent personnel from being struck by flying objects, keep
personnel out of work area.
HAOA110L
Figure 2
HAOA100L
Figure 3

SP002322Track Excavator Maintenance Safety
Page 10
Personal Protective Equipment (PPE)
Do not wear loose clothing and accessories. Secure long hair.
These items can snag on controls or on other parts of
equipment.
Do not wear oily clothes. They are highly flammable.
Some risks to your health may not be immediately apparent.
Exhaust gases and noise pollution may not be visible, but these
hazards can cause disabling or permanent injuries. Breathing
masks and/or ear protection may be required.
Wear a hard hat, safety shoes, safety goggles, mask, leather
gloves, earplugs and other protective equipment, as required.
While working on machine, never use inadequate tools. They
could break or slip, or they may not adequately perform intended
functions.
Correction of Machine Problems
If any machine problems are found during operation and
maintenance (noise, vibration, smell, incorrect gauges, smoke,
oil leakage, etc.), or if any abnormal warming alerts are
displayed on display monitor, stop the machine and take the
necessary corrective actions. Do not operate machine until
problem has been corrected.
Crushing and Cutting
Keep objects away from moving fan blades. Fan blades can
throw and cut objects.
Do not use a wire rope that is kinked or frayed, or a wire rope
with any loss of diameter. Wear leather gloves when handling a
wire rope.
When striking a loose retainer pin, it can fly out and can cause a
serious injury. Make sure that area is clear of personnel when
striking a retainer pin. To avoid injury to your eyes, wear safety
goggles when striking a retainer pin.
Do not put your hand, arm or any other part of your body
between movable parts. If going between movable parts is
necessary, always position and secure work equipment so it
cannot move. Properly support equipment before performing
any work or maintenance under raised equipment.
If control levers are operated, clearance between machine and
work equipment will change and this may lead to serious
damage or can result in death or serious injury. Stay clear of
areas that may have a sudden change in clearance with
machine movement or equipment movement. Stay clear of all
rotating and moving parts. Unless instructed, never attempt
adjustments while machine is moving or while engine is running.
HAOA020L
Figure 4