Daewoo Doosan DX225LC-5 Excavator Service Repair Manual (Serial Number 1001 and Up)

Shop Manual

DX225LC-5 Excavator

Serial Number

DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the world.

Copyright DOOSAN 2014

1001 and Up

950106-01107E October 2014 Original Instructions

1Table

of Contents

1

Safety

1

Track Excavator Maintenance Safety

2

Specifications

1

Specifications

3

General Maintenance

1

General Maintenance Instructions

2

Standard Torques

1

Engine

2

Engine Coolant Heater (Option)

1

Cabin

2

Counterweight

3

Hydraulic Oil Tank

4

Fuel Tank

5

Main Pump

6

Drive Coupling (Main Pump)

7

Main Control Valve

8

Swing Device

9

Joystick Valve (Work Lever)

10

Dozer Joystick Valve

11

Travel Control Valve (with Damper)

12

Solenoid Valve

13

EPPR Valve (One or Two-way)

14

Accumulator

15

Gear Pump (Rotating)

16

One Spool Valve (Rotating)

4

5

Engine

Upper Structure

Table of Contents Page I

6

7

8

9

Lower Structure and Chassis

Front

Hydraulic System

Electrical System

10 Options

11 Schematic

Table of Contents Page II

1

Swing Bearing

2

Center Joint

3

Center Joint (Dozer)

4

Travel Device

5

Track Assembly

6

Dozer System

1

Boom and Arm

2

Bucket

3

Cylinders

1

Hydraulic System

2

Hydraulic System Testing and Adjustment

3

Hydraulic System Troubleshooting

1

Electrical System

1

One Way

2

Two-way

3

Rotating

4

Quick Coupler

5

Two Pump

1

Hydraulic Schematic/Electrical Schematic

Track Excavator Maintenance Safety Edition 1

DX225LC-5

Track Excavator Maintenance Safety 1-1-1

SAFETY INSTRUCTIONS WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation & 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.

SAFETY MESSAGES Replace with Safety Messages Section on pages III and IV in the Doosan Operation & Maintenance Manual.

DX225LC-5

Track Excavator Maintenance Safety 1-1-5

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 work site, 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 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.

Track Excavator Maintenance Safety 1-1-6

DX225LC-5

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.

FG018457

Figure 1

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 must be relieved before maintenance is started.

Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings.

DX225LC-5

Track Excavator Maintenance Safety 1-1-7

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

Track Excavator Maintenance Safety 1-1-8

DX225LC-5

Engine

Edition 1

Engine 4-1-1

DX225LC-5

ENGINE DISASSEMBLY Engine Disassembly

CAUTION AVOID INJURY •

Prepare the necessary tools and genuine parts before engine disassembly.

•

Prepare a shelf to keep removed parts.

•

Keep the working area well lighted and clean.

•

Keep your hands clean at all times during service.

•

Keep parts removed from the engine in the removal order.

•

Make sure that removed parts are not mixed and do not touch each other.

Disassemble the engine according to the following procedure: 1.

Drain coolant.

A.

Check that the engine and radiator is sufficiently cooled down.

B.

Place a container in front of the coolant drain plug.

C.

Remove the radiator cap.

D.

Open the drain valve on the bottom of the radiator to drain coolant.

E.

Remove the coolant drain plugs from the cylinder block and oil cooler.

F.

Drain coolant into the prepared container.

G.

After draining coolant, install the drain plug.

Figure 10

EX1404285

Figure 11

EX1404306

DANGER AVOID DEATH •

Never open the radiator cap while the engine is hot.

If opening the radiator cap while the engine is still hot, hot coolant may spurt, resulting in a severe burn. Open the radiator cap after confirming that the engine is sufficiently cooled down.

•

Put a label on the coolant container not to get mixed with other containers. If you swallow coolant, seek professional medical help immediately.

Engine 4-1-28

DX225LC-5

WARNING AVOID DEATH OR SERIOUS INJURY Used coolant should be discarded according to the local regulations. Never discard used engine oil to the ground, ditch, sewer, river, sea, etc. Such action can pollute the environment. Discarding used engine oil improperly can result in punishment due to violation of the corresponding regulation.

CAUTION AVOID INJURY When changing coolant, make sure that it is not left on any belt or electric part.

2.

Separate the dipstick.

A.

3.

Pull out the dipstick.

Drain engine oil.

A.

Place a container under the engine to collect drained engine oil.

B.

Remove the drain plug from the oil pan and drain engine oil into the prepared container.

C.

Remove the oil filler cap.

D.

Remove the engine oil filter.

E.

After draining engine oil, install the engine oil filter and drain plug.

Drain Valve

EX1403623

Figure 12

WARNING AVOID DEATH OR SERIOUS INJURY Used oil should be discarded according to the local regulations. Never discard used engine oil to the ground, ditch, sewer, river, sea, etc. Such action can pollute the environment. Discarding used engine oil improperly can result in punishment due to violation of the corresponding regulation.

DX225LC-5

Engine 4-1-29

4.

Remove the intercooler.

A.

Remove all the hoses and air pipes from the intercooler.

B.

Unscrew the intercooler mounting bolts to remove the intercooler.

Hot Air by Turbo Charger Compressor Cooled Air to Intake Stake Air Flow by Cooling Fan EX1404312

Figure 13 5.

Remove the cooling fan.

A.

Remove the fan guide and bracket.

B.

Unscrew the flange mounting bolt to remove the flange and cooling fan.

Electronic Clutch Cooling Fan

EX1403625

Figure 14 6.

Remove the belt.

A.

Unscrew the tension adjusting bolts and mounting bolts of the A/C compressor, air compressor and alternator.

B.

Remove the belt.

EX1403626

Figure 15 7.

Remove the engine from the machine.

8.

Disconnect the cables and harnesses of the engine from each sensor.

9.

Remove the alternator and A/C compressor.

A.

Unscrew the mounting bolt to remove the alternator.

B.

Unscrew the idle puller mounting bolt to remove the A/C compressor.

Aircon Compressor Alternator

Figure 16 Engine 4-1-30

EX1403627

DX225LC-5

10.

Remove the breather.

A.

Unscrew the mounting clamp screw to disconnect the rubber hose.

B.

Remove the breather valve assembly.

EX1403628

Figure 17 11.

Disconnect the air pipe and remove the air heater.

A.

Unscrew the mounting bolt to disconnect the air pipe and remove the air heater.

CAUTION AVOID INJURY Never let foreign materials enter the turbocharger.

EX1403629

Figure 18 12.

Remove the fuel filter.

A.

Unscrew the hollow screw from the fuel filter and disconnect the fuel hose.

B.

Unscrew the fuel filter mounting bolt to remove the fuel filter.

EX1403630

Figure 19 13.

Disconnect the intake stake.

A.

Unscrew the mounting bolt to disconnect the air hose.

EX1403631

Figure 20

DX225LC-5

Engine 4-1-31

14.

Separate the intake manifold.

A.

Unscrew the intake manifold mounting bolts to remove the intake manifold from the cylinder block.

B.

Remove the gasket and clean the gasket mounting surface thoroughly with a scraper.

EX1403632

Figure 21 15.

Remove the common rail and high-pressure pipe.

A.

Disconnect the high-pressure pipe between the fuel high-pressure connector and common rail.

B.

Unscrew the common rail mounting bolts to remove the common rail.

CAUTION AVOID INJURY

16.

EX1403633

•

Seal the common rail thoroughly after removing it to prevent foreign materials from entering it.

•

Once the fuel high-pressure disconnected, it cannot be reused.

pipe

Figure 22

is

Remove the fuel high-pressure pump.

A.

Unscrew the fuel high-pressure pump mounting bolts to remove the fuel high-pressure pump.

EX1403634

Figure 23

Engine 4-1-32

DX225LC-5

17.

Remove the EGR valve.

A.

Unscrew the EGR valve mounting bolts to remove the EGR valve and exhaust manifold.

B.

Unscrew the mounting bolts to remove the exhaust pipe from the EGR cooler.

C.

Disconnect the coolant pipe from the EGR valve.

CAUTION AVOID INJURY

EX1403635

Figure 24

Seal the EGR valve and exhaust pipe thoroughly after removing them to prevent foreign materials from entering them.

EX1403636

Figure 25

18.

Remove the EGR cooler.

A.

Unscrew the EGR cooler and bracket connecting bolt to separate the EGR cooler.

B.

Disconnect the pipe and hose from the EGR cooler.

CAUTION AVOID INJURY Seal the EGR cooler thoroughly after removing it to prevent foreign materials from entering it.

19.

EX1403637

Figure 26

Remove dosing module.

Unscrew the mounting bolt of the dosing module to remove it from the UREA tank.

EX1404191

Figure 27

DX225LC-5

Engine 4-1-33

20.

Remove the turbocharger.

A.

Disconnect the intake stake from the turbocharger.

B.

Disconnect the coolant hose from the turbocharger.

C.

Disconnect the oil feed pipe and oil drain pipe between the cylinder block and turbocharger.

D.

Unscrew the turbocharger mounting bolts to separate the turbocharger from the exhaust manifold.

Figure 28 21.

EX1404192

Remove the exhaust manifold.

A.

Unscrew the exhaust manifold mounting bolts to remove the exhaust manifold.

CAUTION AVOID INJURY Do not reuse the removed gasket.

EX1403642

Figure 29 22.

Disconnect the coolant pipe and thermostat.

A.

Unscrew the coolant pipe mounting bolt to disconnect the coolant pipe from the thermostat housing.

B.

Remove the coolant thermostat and O-ring.

C.

Clean the gasket mounting surface of the coolant pipe with a scraper thoroughly.

CAUTION AVOID INJURY

EX1403643

Figure 30

Make sure that the gasket residual does not enter the coolant passage.

Engine 4-1-34

DX225LC-5

23.

Remove the coolant pump.

A.

Unscrew the bracket mounting bolts for the coolant pump and oil cooler.

B.

Unscrew the bolt (1 ea) for the oil cooler.

C.

Unscrew the coolant pump mounting bolts to remove the coolant pump.

D.

Remove the O-ring for the coolant pump.

CAUTION

EX1403644

Figure 31

AVOID INJURY Do not reuse the O-ring.

EX1403645

Figure 32 24.

Remove the start motor.

A.

Unscrew the start motor mounting nut and remove the start motor with care. Be careful not to damage its gear.

EX1403646

Figure 33 25.

Remove the oil filter.

A.

Remove the oil filter cartridge using a special service tool.

Oil Cooler

Oil Filter

EX1403647

Figure 34

DX225LC-5

Engine 4-1-35

26.

Remove the vibration damper.

A.

Unscrew the mounting bolts of the vibration damper and crank pulley in the reverse order to remove the vibration damper assembly.

EX1403648

Figure 35 27.

Remove the cylinder head cover.

A.

Unscrew the cylinder head cover mounting bolts to remove the cylinder head cover.

B.

Unscrew the intermediate cover mounting bolts to remove the intermediate cover.

EX1403649

Figure 36 28.

Remove the rocker arm.

A.

Unscrew the rocker arm bracket mounting bolts in the reverse order to remove the rocker arm assembly.

EX1403650

Figure 37 29.

Remove the push rod.

A.

Remove the push rod.

EX1403651

Figure 38

Engine 4-1-36

DX225LC-5

30.

Remove the fuel injector.

Injector Type

Bolts

A.

Unscrew the fuel high-pressure connector mounting bolts to disconnect the fuel high-pressure connector.

B.

Remove the harness from the injector.

O-ring

C.

Unscrew the injector mounting bracket bolts to remove the injector.

Seal Ring

Fixing Bracket

CAUTION AVOID INJURY

EX1403652

Figure 39

Be careful not to damage the nozzle during removing the injector.

D.

Remove the seal ring from the nozzle hole from the cylinder head.

CAUTION AVOID INJURY To remove the injector, unscrew the fuel high-pressure connector mounting nut to disconnect the fuel highpressure connector completely. Then, unscrew the caliper mounting bolt to remove the injector.

31.

Remove the cylinder head.

A.

Lifting Hook

Unscrew the cylinder head bolts in the reverse order of tightening to remove the cylinder head. –

Step 1: Unscrew the bolt for 1 to 2 threads.

–

Step 2: Unscrew the bolt completely to remove it.

B.

Remove the cylinder head bolts in these two steps.

C.

Keep the removed bolts in order with care, being careful not to damage their threads.

Head Bolt

EX1403741

CAUTION

Figure 40

AVOID INJURY Make sure that the bolts are not hit by each other.

D.

Remove the cylinder head gasket.

E.

Remove foreign materials from the surface of the cylinder head and block.

DX225LC-5

Engine 4-1-37

CAUTION AVOID INJURY Be careful not to damage the mating surface.

F. 32.

Unscrew the mounting bolt of the lifting hook from the cylinder head to remove the lifting hook.

Remove the valve and valve stem seal.

A.

Press the valve spring and retainer with the valve spring compressor to remove the valve cotter.

B.

Remove the valve spring and retainer.

C.

Remove the calipers.

D.

Use a general service tool to remove the valve stem seal.

Valve Spring Copression Jig EX1403742

CAUTION

Figure 41

AVOID INJURY Do not reuse the valve stem seal.

E.

Remove valve.

F.

Unscrew the mounting bolt of the lifting hook from the cylinder block to remove the lifting hook.

EX1403743

Figure 42 33.

Remove the oil cooler.

A.

Unscrew the oil cooler mounting bolts to remove the oil cooler.

EX1403653

Figure 43

Engine 4-1-38

DX225LC-5

34.

Remove the oil pan.

A.

Unscrew the oil pan mounting bolts to remove the oil pan.

B.

Remove the oil pan gasket.

Oil Pan Fixing Bolt

EX1403654

Figure 44 35.

Remove the front oil seal and cover.

A.

Remove the oil seal using a oil seal removing tool.

B.

Unscrew the gear case cover mounting bolt to remove the oil seal cover.

EX1403655

Figure 45 36.

Remove the oil pump and disconnect the pipe.

A.

Unscrew the oil suction pipe mounting bolt to remove the bracket.

B.

Unscrew the oil pump pipe mounting bolts to disconnect the suction pipe and feed pipe.

C.

Unscrew the oil pump mounting bolts to remove the oil pump.

EX1403656

Figure 46 37.

Remove the flywheel.

A.

Unscrew the flywheel mounting bolts and install the guide bolt to remove the flywheel.

B.

Unscrew the bolts in the reverse order of their tightening to remove the flywheel.

EX1403657

Figure 47

DX225LC-5

Engine 4-1-39

38.

Flywheel housing A.

Unscrew the flywheel housing mounting bolts to remove the flywheel housing.

B.

Remove the flywheel housing oil seal.

EX1403658

Figure 48 39.

Remove the cam gear and idle gear.

A.

Unscrew the camshaft gear mounting bolts to remove the camshaft gear.

B.

Unscrew the idle gear mounting bolts to remove the idle gear.

EX1403659

Figure 49 40.

Remove the timing gear case.

A.

Unscrew the timing gear case mounting bolts.

B.

Tap the left and right sides on the back of the contact surface of the timing gear case with a urethane hammer gently to remove the timing gear case.

EX1403660

Figure 50 41.

Remove the piston and connecting rod.

A.

Unscrew the connecting rod cap bolts in the reverse order of their tightening.

NOTE:

Unscrew these bolts in two steps as the cylinder head bolts.

B.

Tap the top and bottom of the connecting rod cap with a urethane hammer lightly to remove the bearing cap and bearing.

C.

Push the connecting rod from the oil pan side toward the cylinder head with a wooden stick to separate the piston assembly.

Engine 4-1-40

EX1403661

Figure 51

DX225LC-5

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42.

D.

Keep the removed pistons in the corresponding cylinder order and make sure that they are not hit by each other.

E.

Install the connecting rod caps to their corresponding connecting rods loosely. Be careful not to mix them.

Remove the piston.

A.

Remove the snap ring of the piston pin using pliers.

EX1403662

Figure 52 B.

Tap the piston pin with a wooden stick gently to remove the piston.

EX1403663

Figure 53 C.

Remove the piston ring using piston ring pliers.

D.

Remove carbon from the piston completely and clean it.

EX1403664

Figure 54

DX225LC-5

Engine 4-1-41

43.

Remove the bearing cap.

A.

Unscrew the bearing cap mounting bolts in the reverse order of their tightening to remove the bearing cap.

NOTE:

B.

Unscrew these bolts with the same method for the cylinder head bolts.

Keep the bearing caps in order.

EX1403665

Figure 55 44.

Remove the crankshaft.

A.

Fit the bolts to both sides of the crankshaft temporarily.

B.

Connect a rope to the bolts and lift the crankshaft with a crane. Be careful not to damage the crankshaft.

C.

Store the removed crankshaft on a safe special shelf so that it is not deformed or damaged.

D.

Remove and store the main bearings in order.

EX1403666

Figure 56

CAUTION AVOID INJURY

45.

•

Make sure that the main bearing and bearing caps are not mixed.

•

Fit the main bearings to their bearing caps temporarily to prevent mixing.

Remove the oil spray nozzle.

A.

Unscrew the oil spray nozzle valve mounting screw to remove the oil spray nozzle.

EX1403667

Figure 57

Engine 4-1-42

DX225LC-5

46.

Remove the camshaft and tappet.

A.

To prevent damage of the camshaft, pull it out while turning it.

B.

Store the removed camshaft on a safe special shelf so that it is not deformed or damaged.

C.

Remove the tappet.

CAUTION AVOID INJURY

EX1403668

Figure 58

Check for damage, scratch and wear. If any abnormal condition is found, replace it.

47.

Remove the cylinder liner.

A.

Be careful not to damage the cylinder block when removing the cylinder liner.

B.

Remove the cylinder liner with its removing tool and hands.

EX1403669

Figure 59

DX225LC-5

Engine 4-1-43