Part of the Doosan Repair Manuals.
Wrenching on a Doosan DX track excavator? This 804-page Doosan DX225NLC shop manual PDF (OEM #K1024241E) is titled for the DX225NLC on its cover, and its shared service sections list the wider family: 180LC, 225LC, 225NLC, 255LC, 300L, 340LC, 420LC, 480LC, and 520LC. Open to full electrical schematics with machine wiring, hydraulic schematics, and a fat hydraulic troubleshooting, testing, and adjustment section that walks you through pressure checks on the axial piston pump, swing motor, travel motor, and main control valve. You also get standard torque tables, swing bearing and reduction gear teardowns, cylinder rebuilds, and complete track assembly service. Torque the DX225NLC counterweight bolts to 150 kg-m (1,085 ft lb), and press track pins to a 0.3 to 0.422 mm link interference. No more chasing a pressure fault with a gauge and a hunch. Bookmarked with a live text layer: type the spec, jump to the chapter, fix the machine. Note that the Specifications section is written for the DX225NLC — the shared removal, disassembly and troubleshooting sections carry the wider model list.
What's Inside This Doosan DX180–DX520 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 5-52 | Track Excavator Safety |
| Specifications | 53-82 | Specification for DX225NLC |
| General Maintenance | 83-120 | General Maintenance Procedures, Standard Torques |
| Upper Structure | 121-224 | Cabin, Counterweight, Fuel Tank, Fuel Transfer Pump, Swing Bearing, Swing Reduction Gear |
| Lower Structure and Chassis | 225-260 | Track Assembly |
| Engine and Drive Train | 261-272 | Drive Coupling (Main Pump) |
| Hydraulic System Troubleshooting, Testing and Adjustment | 275-312 | Safety Precautions, Applicable Models, Hydraulic System - General Notes, Hydraulic Schematic, Operation of Working Components, Boom Operating Circuit |
| Accumulator | 313-360 | Safety Precautions, Applicable Models, General Description |
| Swing Motor | 361-392 | Safety Precautions, Applicable Models, Structure and Operational Principles, Cautions, Maintenance Instructions, Disassembly and Assembly |
| Travel Motor | 393-452 | Safety Precautions, Applicable Models, Operation Manual, General Specifications, Basic Structure and Diagram, Operation Principles |
| Gear Pump | 453-532 | Safety Precautions, Applicable Models, Single Gear Pump, Disassembly, Reassembly |
| Axial Piston Pump | 533-584 | Safety Precautions, Applicable Models, Pump Maintenance, Component Locations, Tools, Tightening Torque |
| Travel Control Valve (with Damper) | 585-610 | Safety Precautions, Applicable Models, General Description, Theory of Operation, Deceleration Valve, Dampening Parts of the Control Section |
| Solenoid Valve Assembly | 611-644 | Safety Precautions, Applicable Models, Package, Functions of Solenoid Valve Assembly Package, Assembly Diagram and Tools Required, Solenoid Valve Diagram |
| Electrical System | 645-780 | Electrical Schematic (DX180LC/DX225LC/ DX225NLC/DX255LC) |
| Attachments | 781-804 | Boom and Arm, Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cooling Fan | 660.4mm (26 in) | p. 72 |
| Bolt Torque | 150 kg•m (1,085 ft lb) | p. 146 |
| Interference between Regular Pin and Link (Standard Interference) | 0.3 - 0.422 mm | p. 240 |
| Clearance between Regular Pin and Bushing (Standard Interference) | 0.18 - 0.74 mm | p. 240 |
| Nominal Output Torque | max. 4000 kgf•m | p. 398 |
| Hydraulic Motor Max. Stroke Capacity | 183.9 cc/rev | p. 398 |
| Recommended quantity of oil for the case | 1.2 liter | p. 407 |
| Hydraulic oil change interval | 1000 hours or 1 year | p. 408 |
| Nominal sectional area of wire core less insulator | 0.85 mm2 | p. 655 |
| Boom Foot Pin Clearance Limit | 1.5 mm | p. 789 |
| Boom Cylinder Head Pin Clearance Limit | 1.5 mm | p. 789 |
| Fuel Tank Capacity | 340 liters | p. 70 |
Doosan DX180–DX520 Series Common Problems This Manual Covers
Doosan DX225LC weak travel power, tracks slow under load and machine crawls uphill
Check travel motor drain line back pressure; normal is 2 kgf/cm2 with peaks no higher than 7 kgf/cm2, listed on page 407. Test the 2-speed switching pressure against the 20 to 70 kgf/cm2 range on page 398. Drain the final drive case and refill with 3.3 liters if metal shows on the plug.
Manual Section: Travel Motor Troubleshooting p. 407Jerky uneven track movement with hydraulic shudder during travel and slow swing response
Drain a hydraulic oil sample before chasing valves. Replace the oil if water content exceeds 0.1 percent or impurities pass the change standards on page 408, and follow the 1000 hour or 1 year change interval. Bleed air at the pump after any filter change, then cycle each track slowly to purge the circuit.
Manual Section: Hydraulic System Troubleshooting p. 408Hydraulic power loss with oil overheating after a few hours of digging
Measure the travel motor case temperature during continuous operation; anything above the 80 degree C standard on page 410 points to internal leakage or contaminated oil. Clean the oil cooler fins with low-pressure air, verify oil condition against the change standards, and confirm reservoir level before condemning the main pump.
Manual Section: Hydraulic Problems Troubleshooting p. 410Sluggish joystick response and low pilot pressure, boom and arm hesitate before moving
Test pilot pressure at the accumulator first; on DX225NLC machines the charge pressure spec is 10 kg/cm2, found on page 320. Inspect the gear pump suction line for air leaks and listen for cavitation whine at idle. If pilot pressure holds steady, work through the solenoid valve assembly before touching the joysticks.
Manual Section: Solenoid Valve Assembly Troubleshooting p. 320Loose tracks jumping the sprocket, worn pins and bushings clicking during travel
Measure pin and bushing wear before ordering an undercarriage kit. Standard clearance between the regular pin and bushing runs 0.18 to 0.74 mm, shown on page 240. Replace any set past that range, grease all fittings daily after water exposure, and relieve track tension carefully since the grease is under high pressure.
Manual Section: Lower Structure and Chassis p. 240Frequently Asked Questions
How do I clear hydraulic pressure on a Doosan DX225NLC before service?
To clear hydraulic pressure, park the machine on level ground, lower the attachment to the ground, and shut down the engine. Turn the starter switch to the 'I' (ON) position and fully stroke the work levers (joysticks) in all directions to relieve pressure from the accumulators. Finally, set the safety lever to the 'LOCK' position. p. 129
What does error code V201 mean on a Doosan DX225NLC?
Error code V201 indicates a gauge panel communication error. The correct resistance for the CAN line is 60 ± 5 ohms, measured between terminals CN7-4 and CN7-5. p. 692
What is the fuel tank capacity for the DX225NLC?
The fuel tank capacity for the DX225NLC is 340 liters (90 U.S. gal). p. 153
What is the tightening torque for the main relief valve on the DX225NLC?
The tightening torque for the main relief valve is 7.95 - 8.97 kg•m (58 - 65 ft lb). p. 525
How often should the gear oil in the travel motor be changed?
The first gear oil change should be performed after 500 operating hours, and subsequent changes should occur every 1000 operating hours or once a year. p. 409
What exactly do I receive with this Doosan DX180–DX520 Series Shop Manual?
This is a 804-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Is printing allowed for this Doosan DX180–DX520 Series Shop Manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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