Doosan DX225LC-5 Operations Manual
Operation &
Maintenance
Manual
EXCAVATOR
DX225LC-5
Serial Number 1001 and Up
950106-01108FNA
December 2019
Operation and Maintenance Manual
DX225LC-5 Excavator
Serial Number 1001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-01108FNA
December 2019
Original Instructions Copyright DOOSAN 2019©
1REVISION
Date ltems Location
Oct. 2018 Revised text & figures Operating Controls - User Menu - Machine Configuration
Oct. 2018 Revised text Operation - Engine Start
Oct. 2018 Revised text & figures
Feb. 2019 Revised text
Aug. 2019 Revised text
Dec. 2019 Revised text & figures Operation - Quick Coupler Operation
Inspection, Maintenance and Adjustment - Fluid Capacities,
Change Pilot Filter, Track Tension
Inspection, Maintenance and Adjustment - Service data
comment add.
Inspection, Maintenance and Adjustment - Maintenance
Intervals.
Table of Contents
Foreword ....................................................................................0-1
AEM Safety Manual (North America Only) ........................................ 0-6
Federal and California Emission Control Systems............................. 0-7
Safety..........................................................................................1-1
Safety Decals..................................................................................... 1-2
General ............................................................................................ 1-18
Transportation.................................................................................. 1-31
Operation ......................................................................................... 1-33
Maintenance .................................................................................... 1-53
Environment and Circumstances ..................................................... 1-69
Operating Controls....................................................................2-1
Component Locations ........................................................................ 2-2
Operator's Area.................................................................................. 2-6
Operational Controls and Panels ....................................................... 2-8
Display Monitor ................................................................................ 2-26
User Menu ....................................................................................... 2-54
Heater and Air Conditioner Control Panel........................................ 2-96
Stereo ............................................................................................ 2-102
Miscellaneous Electrical Devices................................................... 2-103
Seat Adjustment............................................................................. 2-105
Engine Emergency Stop Switch..................................................... 2-108
Emergency Exit Glass Breaking Tool ............................................ 2-109
Miscellaneous Convenience Devices ............................................ 2-110
Miscellaneous Access Covers and Doors...................................... 2-117
DX225LC-5
Air Gun and Compressor (Optional) .............................................. 2-119
Table of Contents
I
Operation....................................................................................3-1
To Operate a New Excavator............................................................. 3-1
Starting and Stopping Engine ............................................................ 3-2
Safety Lever..................................................................................... 3-17
Travel ............................................................................................... 3-18
Operating Instructions...................................................................... 3-24
Operating Precautions ..................................................................... 3-40
Parking Excavator............................................................................ 3-47
Towing Procedure............................................................................ 3-48
Attachments ..................................................................................... 3-49
Hydraulic Attachments (Optional) .................................................... 3-52
Lifting Objects .................................................................................. 3-70
Lifting Objects with Quick Coupler ................................................... 3-72
Operation Under Abnormal Conditions ............................................ 3-74
Long Term Storage .......................................................................... 3-82
Inspection, Maintenance and Adjustment...............................4-1
Maintenance Information ................................................................... 4-1
Machine Setup Position for Maintenance .......................................... 4-5
Maintenance Handling Access........................................................... 4-7
Handling Oil, Fuel, DEF (AdBlue), Coolant........................................ 4-8
Electrical System Maintenance........................................................ 4-14
Recommend Fuel, Coolant, and Lubricant ...................................... 4-15
Fluid Capacities ............................................................................... 4-21
Table of Recommended Lubricants ................................................. 4-22
Maintenance Intervals...................................................................... 4-24
10 Hour / Daily Service .................................................................... 4-27
50 Hour / Weekly Service ................................................................ 4-41
250 Hour / Monthly Service.............................................................. 4-45
500 Hour / 3 Month Service ............................................................. 4-50
1,000 Hour / 6 Month Service .......................................................... 4-61
DX225LC-5Table of Contents
II
2,000 Hour / Yearly Service ............................................................. 4-71
4,000 Hour / Biennial Service .......................................................... 4-78
4,500 Hour / Biennial Service .......................................................... 4-79
12,000 Hour / 6 Year Service........................................................... 4-82
Air-conditioning System ................................................................... 4-83
Bucket .............................................................................................. 4-84
Electrical System ............................................................................. 4-86
Engine Cooling System.................................................................... 4-90
Fuel Transfer Pump (Optional) ........................................................ 4-94
Handling of Accumulator.................................................................. 4-97
Track Tension .................................................................................. 4-98
Venting and Priming Hydraulic System.......................................... 4-100
Maintenance in Special Conditions................................................ 4-102
Transportation ...........................................................................5-1
Loading and Unloading ...................................................................... 5-2
Lifting Machine................................................................................... 5-8
Specification ..............................................................................6-1
Standard Specification ....................................................................... 6-1
Overall Dimensions............................................................................ 6-2
Disassembled Parts, Dimension and Weight..................................... 6-4
Ground Pressure................................................................................ 6-6
Digging Force..................................................................................... 6-7
Working Range .................................................................................. 6-8
Excavator Rated Lift Capacity Tables.............................................. 6-12
Approximate Weight of Workload Materials..................................... 6-59
Index ...........................................................................................7-1
DX225LC-5
Table of Contents
III
IV
DX225LC-5Table of Contents
This Operation & Maintenance Manual was written to give owner
or operator instructions on safe operation and maintenance of
DOOSAN equipment. READ AND UNDERSTAND THIS
OPERATION AND MAINTENANCE MANUAL BEFORE
OPERATING YOUR DOOSAN EQUIPMENT. Keep this manual
in the cabin so it is always available. If it is lost, order another
one from your DOOSAN distributor.
If there are any questions, contact your DOOSAN distributor.
This manual may illustrate options and accessories not installed
on your equipment.
Any modification made without written authorization or approval
from DOOSAN can create a safety hazard.
Always replace parts with genuine DOOSAN parts or DOOSAN
authorized replacement parts.
Intended Use
The machine is intended to be used under normal conditions for
applications described in this manual. If it is used for other
purposes, or in potentially hazardous environments, special
precautions must be followed and the machine must be
equipped for such use. Examples include, but are not limited to,
are: falling object guards, work lights, etc. Do not engage in
prohibited uses as described in this manual. Contact your
DOOSAN distributor for further information.
Foreword
Engine and Emission Control System
Maintenance
Proper inspection, maintenance and repair is essential to
keeping engine and machine systems properly operating. This
includes proper inspection and maintenance of the machine's
emission control system. This could include machine and engine
components, such as an EGR (Exhaust Gas Recirculation)
system, fuel system, turbocharger, electrical system, air intake
system and/or cooling system.
As a heavy-duty off-road diesel engine owner, you are
responsible for performing required maintenance. The required
maintenance procedures are outlined in this Operation &
Maintenance Manual, or Shop Manual. Do not remove, alter, or
render inoperative, any emission control system.
DX225LC-5
Foreword
0-1
Machine Capacity
Do not exceed machine capacity by modifying machine or using
unapproved attachments.
Exceeding machine capacity can adversely affect machine
performance characteristics such as: stability, system
certifications such as brakes and steering, the Roll-over
Protective Structure (ROPS) and can result in death or serious
injury. Contact your DOOSAN distributor for further information.
Attachments
These and other attachments are approved for use on this
machine. Do not use unapproved attachments. Attachments not
manufactured by DOOSAN may not be approved. See your
DOOSAN distributor for information about approved
attachments and attachment manuals.
•Buckets
• Hydraulic Breakers
• Grapples
• Plate Compactors
• Quick Couplers
California Proposition 65
Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth
defects or other reproductive harm.
• Always start and operate the engine in a wall-ventilated
area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
This product can expose you to chemicals including lead, which
is known to the State of California to cause cancer and birth
defects or other reproductive harm.
For more information go to www.P65Warning.ca.gov.
0-2
DX225LC-5Foreword
Product Identification Number (PIN)
EX1403864
Figure 1
EX1301247
Figure 2
Figure 3
EX1301248
Doosan Infracore Co., Ltd.
7-11, Hwasu-dong, Dong-gu,
Incheon, Korea
PRODUCT IDENTIFICATION NUMBER
⣆㔲#⎇ᵮ#ᴲ㛢
MADE IN KOREA
⣆㔲ᬯ
MODEL
950209-02977
Operating
Identification
Construction
Year of
Number
Product
Power
Engine
7-11, Hwasu-dong, Dong-gu,
Doosan Infracore Co., Ltd.
Incheon, Korea
kW
Mass
Model Name
Machine Type
Made in Korea
kg
First Year
of Service
950205-01325A
A PIN number is stamped on upper frame under boom foot
(
Figure 1). It is also stamped on a product identification plate
(Figure 2) on outside of cabin on right-hand side.
NOTE: Record these numbers and their locations. These will
be required whenever warranty or service work is
requested. Keep these numbers on file in case
machine is stolen.
Component Serial Numbers
There are many serial numbers on each traceable component of
the machine. Record these numbers and their locations. These
will be required whenever warranty service work is requested.
DX225LC-5
Foreword
0-3
Engine Identification
1
2
EX1403746
Figure 4
Engine Data Plate
The engine data plate provides important facts about the engine.
The engine serial number (ESN) and control parts list (CPL)
provide information for service and ordering parts. The engine
data plate must not be changed unless approved by DOOSAN.
The engine data plate and engine serial number are located on
the head cover. Have the following engine data available when
communicating with a DOOSAN Authorized Repair Location.
The following information on data plate is mandatory when
sourcing service parts:
Reference
Number
1 Engine Data Plate
2 Engine Serial Number
Description
Your Machine Serial Numbers
Product Identification Number (PIN)
Machine Serial No.
Engine Serial No.
Main Pump
Swing Motor
Travel Motor
Main Control Valve
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.
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 must be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
0-4
DX225LC-5Foreword
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.
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.
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.
NOTE: The word "NOTE" identifies information for effective
use.
DX225LC-5
Foreword
0-5
AEM SAFETY MANUAL
Figure 5
(NORTH AMERICA ONLY)
The AEM Safety Manual delivered with the machine gives
general safety information.
The AEM Safety Manual must be read and understood before
beginning operation or maintenance and is not intended to
replace the Operation & Maintenance Manual delivered with the
machine.
DX225LC-5Foreword
0-6
FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS
Limited Warranty for Non-road Engines (CI) (FDICL05.8LEA (DL06P))
Owner’s Warranty Rights and Obligations
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (ARB), and DOOSAN
INFRACORE are pleased to explain the Federal and California Emission Control System Warranty on your
2015MY to 2017MY non-road engine. DOOSAN INFRACORE has designed, built and equipped the engine so as
to conform at the time of sale with all applicable regulations of the EPA and of the California ARB. In California,
new heavy-duty off-road engines must be designed, built and equipped to meet the State’s stringent anti-smog
standards.
DOOSAN INFRACORE must warrant to the initial owner, and each subsequent owner, the emission control
system on your engine for the periods of time listed below provided there has been no abuse, neglect, improper
maintenance or unapproved modifications of your engine. Your emission control system may include those parts
listed below:
1. Fuel Metering System
Fuel Supply Pump (HP Pump), Injector, Common Rail, Glow Plug
2. Air-Induction System
Intake Manifold, Turbocharger System
3. Exhaust Gas Recirculation (EGR) System
EGR Valve, EGR Cooler
4. Catalyst or Thermal Reactor System
Diesel Oxidation Catalyst (DOC), Exhaust Manifold, SCR System, Catalyst, NOx Sensor
5. Positive Crankcase Ventilation (PCV) System
Right Head Cover
6. Electronic Control System
ECU, Cam/ Crank Sensor, Coolant Temperature Sensor, MAF Sensor, MAP Sensor (Manifold Pressure
Sensor), Inlet Boost Temperature Sensor, Fuel Temperature Sensor, Common Rail Pressure Sensor
7. Miscellaneous Items Used In Above Systems
Temperature and time sensitive valve and switches
Solenoids and wiring harnesses
Hoses, clamps, fittings and tubing, sealing gasket
Pulleys, belts and idlers
Emission control information labels
Where a warrantable condition exists, DOOSAN INFRACORE CONSTRUCTION EQUIPMENT AMERICA
(hereafter "DICEA") will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts, and
labor.
DX225LC-5
Foreword
0-7
Manufacturer's Warranty Coverage
The 2015MY to 2017MY heavy-duty off-road engines are warranted for five years or 3,000 hours of operation,
whichever occurs first. If any emission-related part on your engine is defective, the part will be repaired or
replaced by DICEA.
The warranty period shall begin on the date the machine is delivered to the first retail customer.
Owner’s Warranty Responsibilities
As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance
listed in the Operation and Maintenance Manual. DOOSAN INFRACORE and DICEA recommends that you
retain all receipts covering maintenance on your heavy-duty off-road engine, but DOOSAN INFRACORE and
DICEA cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all
scheduled maintenance.
As the heavy-duty off-road engine owner, you should however be aware that DOOSAN INFRACORE and DICEA
may deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect,
improper maintenance or unapproved modifications.
Your engine is designed to operate on Ultra Low Sulfur Diesel Fuel Only. Use of any other fuel may result in
your engine no longer operating in compliance with the EPA’s emissions requirements.
You are responsible for initiating the warranty process. The EPA and California ARB suggest that you present
your heavy-duty off-road engine to a DICEA dealer as soon as a problem exists. The warranty repairs should be
completed by the dealer as expeditiously as possible.
If you have any questions regarding your warranty rights and responsibilities, you should contact your nearest
authorized DICEA dealer or contact DICEA at
Doosan Infracore Construction Equipment North America
2905 Shawnee Industrial Way
Suwanee, GA 30024
USA
1-800-743-4340
0-8
DX225LC-5Foreword
1Safety
DX225LC-5
Safety
1-1
SAFETY DECALS
Safety decals are attached to the machine to alert the operator
or maintenance person about potential hazards, the
consequences of potential injury, and instructions and/or actions
required to avoid the hazard. The location of the safety decals
and the description of the decals are reviewed in the following
section. Please become familiarized with all safety decals and
their messages.
Make sure that all the safety decals are in their correct location
and legible. Clean or replace the safety decals if they are
damaged, missing, or the texts and pictorials are not legible.
When you clean the safety decals, use a soft cloth, water, and
soap. Do not use solvent, gasoline, or other harsh chemicals to
clean the safety decals because this could loosen the adhesive
that secures the decals to the machine. Remember, if a safety
decal is attached to a part that is replaced, install a new safety
decal on the replacement part.
This machine uses safety decals with and without text. The type
and number of safety decals can vary depending upon
geographical regions and machine models.
Safety Decals With Text
Safety decals with text consist of a signal word, pictorial and a
text message panel. In some cases, a pictorial panel may not be
part of the safety decal.
1-2
DX225LC-5Safety
Safety Decals Without Text (No-Text)
Horizontal Configuration
Vertical Configuration
Hazard
Panel
Avoidance
Panel
Hazard
Panel
Avoidance
Panel
FG018723
Figure 1
Safety decals without text consist of a hazard panel(s) and
avoidance panel(s). Hazard panels are located at the top or left
side and the avoidance panels are located at the bottom or right
side of the decal depending on its configuration. The hazard
panels use a black triangular band and a pictorial to identify the
hazard and the potential consequences of failure to follow the
instructions. Avoidance panels use pictorials and/or prohibition
signs to identify the actions necessary to avoid the hazard.
A safety decal may contain more than one hazard panel and
more than one avoidance panel.
DX225LC-5
Safety
1-3
Information and Location for Safety Decals
227
DS1801352
2928 21 15 16 1
24
Figure 2
DX225LC-5Safety
1-4
Information and Location for Safety Decals (Continued)
Figure 3
465
25
12
26
19, 7, 8
EX1403849
DX225LC-5
Safety
1-5
1. General Hazard (950205-03804)
EX1301176
1
2
3
WARNING
AVOID DEATH OR SERIOUS INJURY
• Never use excavator without instructions.
• Read Operation & Maintenance Manual before
operation.
• Sound the horn to alert bystanders before
operating.
• Always fasten your seat belt.
• Explosion or electrocution can occur if machine
contacts utility lines or pipes. Check for overhead
or underground lines before operating.
• Secure and lock front window when it is in raised
position.
• Attachment interference can cause death, serious
injury or machine damage. Check attachment to
machine clearance through full working cycle
before operation.
• Keep bystanders out of swing area and travel
path and always look in the travel direction.
• Ensure mirrors and rear view camera are clean
and working properly.
• Never operate machine from outside the
operator's position.
• TO LEAVE THE EXCAVATOR:
1) Lower the attachment and dozer blade (if
equipped) to the ground and make sure all
controls are in neutral.
2) Stop engine and remove key.
3) Lower safety lever to LOCK position.
1-6
DX225LC-5Safety
2. Warning Tag - "Do Not Operate" (950205-03802)
EX1301180
EX1301181
WARNING
AVOID DEATH OR SERIOUS INJURY
• Stop engine and remove key.
• Attach "DO NOT OPERATE" warning tag to the
controls before servicing the machine.
• Do not operate when performing inspection or
maintenance.
3. Keep Bystanders Away (950205-03803)
WARNING
AVOID DEATH OR SERIOUS INJURY
• Keep out of swing area and travel path.
• Always look in the travel direction.
EX1301177
• Make sure swing area is clear of bystanders and
objects.
4. Hot Pressurized Fluid (950205-03781)
WARNING
HOT PRESSURIZED FLUID CAN CAUSE
SERIOUS BURNS
• Do not loosen or open cap when hot.
• Before opening:
1) Turn engine off.
2) Allow machine to cool.
3) Tip cap and open slowly to relieve pressure.
5. Entanglement in Rotating Parts (950205-03791)
WARNING
ROTATING PARTS CAN CAUSE DEATH OR
SERIOUS INJURY
Keep away from belt and rotating parts. Stop engine
before servicing.
DX225LC-5
Safety
1-7
6. Rotating Fan (950205-03788)
WARNING
CONTACT WITH ROTATING FAN CAN CAUSE
DEATH OR SERIOUS INJURY
Keep away from fan and rotating parts. Stop engine
before servicing.
7. Battery Explosion (950205-03785)
WARNING
AVOID DEATH OR SERIOUS INJURY
• Read and follow instructions in Operation &
Maintenance Manual for battery maintenance.
• Keep arcs, sparks, flames, and lighted tobacco
away.
• Do not store metal tools or flammable materials
on or around batteries.
• Wear safety goggles and rubber gloves when
working with batteries.
• If battery acid contact occurs:
1) Flush your skin with water immediately and
apply baking soda or lime to neutralize the
acid.
950205-03788
EX1301182
EX1301183
2) Flush your eyes with water for 10 - 15
minutes.
3) Get medical attention immediately.
8. Battery Disconnection (950205-03784)
IMPORTANT
AVOID ELECTRICAL COMPONENT DAMAGE
Disconnecting the battery while the engine is running
can cause damage to electrical components.
Disconnect battery only when the engine is turned
OFF.
1-8
DX225LC-5Safety
9. Flying Debris or Objects (950205-03866)
EX1301185
EX1301186
EX1301187
WARNING
HIGH-PRESSURE GREASE CAN CAUSE
DEATH OR SERIOUS INJURY
• Track adjusting systems use grease under highpressure which can penetrate body if improperly
serviced.
• NEVER LOOSEN track tension grease valve more
than one complete turn from the fully tightened
position.
• Bleed off pressure slowly and keep body away
from grease valve.
• Wear eye protection.
• Read and follow instructions in Operation &
Maintenance Manual for more information on
track adjustment.
10. Crush Hazard (950205-03805)
WARNING
AVOID DEATH OR SERIOUS INJURY
Stay clear of the boom, arm, and attachment.
11. Pressurized Gas and Fluid (950205-03782)
WARNING
AVOID DEATH OR SERIOUS INJURY
• Heat or impact can cause the accumulator to
explode.
• Keep away from flame.
• Do not weld on or drill into accumulator.
DX225LC-5
Safety
1-9
12. Fall Hazard (950205-03783)
WARNING
AVOID DEATH OR SERIOUS INJURY
Do not step in this area.
13. Hot Surface (950205-03777)
WARNING
HOT SURFACE CAN CAUSE SERIOUS BURNS
• Do not touch hot surface.
• Allow to cool before servicing.
EX1301188
EX1301189
14. Emergency Exit (950205-03810)
IMPORTANT
If primary exit is blocked, use glass breaking tool to
break glass for secondary exit.
EX1301190
1-10
DX225LC-5Safety
15. ISO Control Pattern (950205-03860)
WARNING
AVOID INJURY OR DEATH
Read and understand the Operation & Maintenance
Manual for more information.
Refer to "Operating Instructions" section of this
manual for details regarding the work levers
(joysticks) control functions.
BHL Control Pattern (US Only) (950205-03868)
WARNING
AVOID INJURY OR DEATH
Read and understand the Operation & Maintenance
Manual for more information.
Refer to "Operating Instructions" section of this
manual for details regarding the work levers
(joysticks) control functions.
16. Impact Hazard (Optional) (950205-03963)
WARNING
AVOID DEATH OR SERIOUS INJURY
• Activating the Intelligent Floating Boom Control
with the tracks raised up can cause the machine
to drop suddenly.
• Do not activate Intelligent Floating Boom Control
when tracks are raised.
• Do not raise tracks when control is activated.
Refer to "Intelligent Floating Boom Control (Optional)"
section of this manual for more information.
EX1301192
EX1301193
DX225LC-5
Safety
1-11
17. Ultra Low Sulfur Diesel Fuel (Optional)
950205-03861
(950205-03863, 950205-03864)
IMPORTANT
Only use Ultra Low Sulfur Diesel (ULSD) fuel with this
machine.
ULTRA LOW SULFUR
DIESEL FUEL ONLY
EX1301196
EX1301194
18. ROPS Warning (Optional) (950205-03861)
WARNING
AVOID DEATH OR SERIOUS INJURY
• Do not weld on or drill holes in the protective
structure.
• Replace ROPS, if damaged or modified.
950205-03861
EX1301197
1-12
DX225LC-5Safety
Loading...