Part of the Doosan Repair Manuals.
Looking for the Doosan DX225LC shop manual PDF? This is the 798-page factory shop manual (OEM #K1015439E) for the DX225LC track excavator, serial number 5001 and Up. It opens with a full specification section: 21.5 metric ton shipping weight, DL06 engine rated 150 ps at 1,900 rpm, 400 liter fuel tank and 140 liter hydraulic reservoir. The electrical section carries per-system circuit diagrams, electric power, power mode, work mode, power boost, lighting, air conditioner and heater, overload warning and audio, plus EPOS panel diagnostics and failure-log procedures. The hydraulic section adds function-by-function circuit diagrams alongside troubleshooting, testing and adjustment, with pilot pressure set to 40 ± 5 bar at the gear pump and main relief running 330 kg/cm2 normal, 350 kg/cm2 with Pressure Up. You also get teardown and reassembly steps for the cylinders, swing motor, swing reduction gear, travel motor, main control valve and axle piston pump, each with wear limits and tolerances. Fill the swing reduction gear with 3.8 liters of EP80W/90, then torque the eleven gearbox-to-frame bolts to 55 kg-m. Bookmarked with a real text layer, so you can search any spec and pull it up on your phone in the cab.
What's Inside This Doosan DX225LC Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 5-48 | Applicable Models and Serial Number Ranges, General Safety Essentials, Location of Safety Labels, Safety Precautions for Lifting in Digging Mode |
| Specifications | 49-74 | Component Locations, General Dimensions and Working Range, General Specifications, DL06 Engine Performance Curves (DIN 6270), Performance Tests and Excavator Performance Standards |
| General Maintenance | 75-110 | Welding Precautions, Hydraulic System Cleanliness and Oil Leaks, Bearing Inspection and Wear Patterns, Standard Torque Values for Metric and U.S. Fasteners, Hose Clamp Torques |
| Upper Structure | 111-216 | Cabin, Counterweight, Fuel Tank and Fuel Transfer Pump, Swing Bearing, Swing Reduction Gear: Removal, Installation, Wear Limits and Gear Oil Service |
| Lower Structure and Chassis | 217-250 | Track Assembly: Track Tension, Track Shoes and Links, Front Idler, Lower and Upper Rollers, Cleaning and Inspection with Wear Limits |
| Engine and Drive Train | 251-262 | Drive Coupling (Main Pump): General Description, Special Tools, Removal and Installation |
| Hydraulic System Troubleshooting and Testing | 263-320 | Hydraulic System General Notes, Operation of Working Components, Procedural Troubleshooting Baselines, Pilot Pressure and Power Mode Valve, Circuit Diagrams for Each Working Function, Accumulator, Center Joint (Swivel) |
| Cylinders, Swing and Travel Motors | 321-450 | Cylinder Disassembly and Reassembly with Special Tools, Swing Motor Operation and Maintenance, Travel Motor Operation, Hydraulic Circuit Diagram, Gear Oil Service and Wear Limits |
| Pumps, Control Valves and Hydraulic Schematic | 451-642 | Gear Pump, Main Control Valve Testing, Adjustment and Rebuild, Axle Piston Pump, PTO Server, Remote Control Valve (Joystick), Travel Control Valve with Damper, Solenoid Valve Assembly, Breaker EPPR Valve, Hydraulic Schematic Section |
| Electrical System | 643-774 | Electric Power, Engine Starting, Preheating, Stop and Charging Circuits, Power Mode, Work Mode and Power Boost Circuit Diagrams, Lighting, Air Conditioner and Heater, Overload Warning and Audio Circuit Diagrams, EPOS Panel Diagnostics and Failure Logs |
| Attachments | 775-798 | Boom and Arm: Front Attachment Pin Specifications, Removal and Installation; Bucket: Tooth Inspection and Replacement, O-Ring Replacement, Bucket Reversal |
Every system also includes applicable models and safety precautions.
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine Model | DL06 | p. 64 |
| Engine Power (DIN 6270) | 150 ps @ 1,900 rpm (148 hp) | p. 64 |
| Max. Engine Torque | 68 kg•m @ 1,400 rpm (492 lb•ft) | p. 64 |
| Shipping Weight | 21.5 metric tons (47,399 lb) | p. 61 |
| Counterweight Weight | 4,100 kg (9,039 lb) | p. 61 |
| Fuel Tank Capacity | 400 liters (105.7 U.S. gal) | p. 61 |
| Hydraulic System Capacity | 240 liters (63.4 U.S. gal) | p. 61 |
| Hydraulic Reservoir Capacity | 140 liters (37 U.S. gal) | p. 61 |
| Main Relief Pressure (Normal) | 330 kg/cm2 (4,689 psi) | p. 67 |
| Main Relief Pressure (Pressure Up) | 350 kg/cm2 (4,970 psi) | p. 67 |
| Pilot Pressure at Gear Pump | 40 ± 5 bar (580 ± 73 psi) | p. 279 |
| Pilot Pressure at Joystick | 23.5 ± 1.5 bar (341 ± 22 psi) | p. 279 |
| Pilot Accumulator Charge Pressure | 10 kg/cm2 (140 psi) | p. 307 |
| Swing Reduction Gear Oil | 3.8 L EP80W/90 | p. 212 |
| Swing Gearbox to Frame Bolt Torque | 55 kg•m (398 ft lb) | p. 215 |
| Travel Reduction Gear Oil Change Quantity | 3.3 liters SAE #90 | p. 407 |
| Main Relief Valve Plug Torque | 7.95 - 8.97 kg•m (58 - 65 ft lb) | p. 527 |
| Solenoid Valve Coil Resistance | 26.7 Ω @ 20°C | p. 623 |
Doosan DX225LC Common Problems This Manual Covers
Doosan DX225LC one track slower than the other, machine pulls sideways and loses power climbing slopes
Drain the travel reduction gear on the slow side and inspect the oil for metal flakes. Refill through the PT1/2 filling port with 3.3 liters of SAE #90 extreme pressure gear oil, the change quantity listed on page 407. Doosan calls for the first change at 500 operating hours and every 1,000 hours after that. If drift continues, swap the travel supply hoses side to side to isolate motor from valve.
Manual Section: Travel Motor SP000922 p. 407Hydraulic functions strong when cold but turn weak and slow once oil heats up during digging
Check the reservoir oil level first; the reservoir holds 140 liters per the spec table on page 61. Warm the machine, then gauge main relief pressure and confirm 330 kg/cm2 against the performance test values on page 67, using the test procedure that begins on page 263. If pressure drops when hot, replace the return filter and blow out the oil cooler before condemning the pump.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment SP000913 p. 263Swing gearbox whines and runs hot, upper structure hesitates before it starts to rotate
Drain the swing reduction gearbox and look for burned or metallic oil. Refill through the oil inlet with 3.8 liters of EP80W/90 gear oil as specified on page 212. When you regrease the swing motor, reseal the PT1/4 grease plug with Teflon tape and torque it to 220 kgf.cm per page 213. If the whine persists with fresh oil, work through the gear wear limits in the troubleshooting steps on page 182.
Manual Section: Swing Reduction Gear SP000915 p. 182Engine hard to start or stalls under load after sitting, water separator keeps filling up
Drain the water separator daily and check the tank sump; the 400 liter fuel tank listed on page 61 collects condensation when parked half full. Replace the main fuel filter and pre-filter, then bleed the system. If trouble returns, pull the tank drain valve and flush sediment following the removal procedure starting on page 135.
Manual Section: Fuel Tank SP001005 p. 135Joysticks move freely but attachment and travel functions stay dead after startup
Test each solenoid valve coil with a multimeter; a good coil reads 26.7 ohms at 20°C per the chart on page 623. Verify pilot accumulator charge pressure at 10 kg/cm2, referenced on page 307, since a flat accumulator starves pilot supply at low idle. Replace any coil out of spec and retest pilot pressure at the gear pump, which should read 40 ± 5 bar on page 279.
Manual Section: Solenoid Valve Assembly SP000445 p. 623Frequently Asked Questions
How do I clear an error code on the Doosan DX225LC?
To delete memorized past failure records, navigate to the 'Delete Fail Log' mode in the special menu. When the 'YES' button is pressed, the memorized record will be deleted, and the screen will move to the previous menu after 3 seconds. p. 686
What are the replacement specifications for the pilot filter?
The pilot circuit is equipped with a 10-micron full-flow filter. The disposable element traps and removes impurities from the oil in the system. p. 271
What is the tightening torque for the main relief valve on the DX225LC?
The main relief valve should be tightened to a torque of 7.95 - 8.97 kg•m (58 - 65 ft lb). These values are based on the use of lubricated threads. p. 527
What is the recommended interval for changing the gear oil in the travel motor?
The first gear oil change should be performed after 500 operating hours. Subsequent oil changes should be performed every 1000 operating hours or once a year. p. 407
How do I adjust the pilot pressure on the DX225LC?
To adjust the gear pump relief pressure, loosen the lock nut and turn the set screw clockwise to increase pressure, or counterclockwise to decrease it. The pilot pressure at the pump should be 40 ± 5 bar (580 ± 73 psi). p. 279
What exactly do I receive with this Doosan DX225LC Shop Manual?
A 798-page Shop Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Can I print a copy of this Doosan DX225LC Shop Manual for the shop?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
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