Part of the Doosan Repair Manuals.
Need factory answers for your Doosan DX225LC? This 810-page shop manual PDF (OEM #950106-00075E, 2010) also covers the DX225NLC, DX300LC, DX300LCA, DX340LC, DX350LC, DX420LC, DX480LC, and DX520LC track excavators. Inside: full electrical schematics for the e-EPOS control system, complete hydraulic schematics, and page after page of troubleshooting for swing motors, travel motors, and axial piston pumps. You get teardown and reassembly steps for the swing bearing, track assembly, center joint, main control valve, and cylinders, plus a dedicated section on pilot pressure adjustment and flow meter testing. Torque 1/2-inch split flange bolts to 15-18 ft lb and set worm-drive hose clamps under 44 mm to 40-50 in lb. No more chasing a swing fault with a multimeter and a prayer. Bookmarked with a full text layer: search any spec, jump to any section, get wrenching.
What's Inside This Doosan DX225LC-DX520LC Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7-50 | Track Excavator Safety (Safety Precautions, Applicable Models, To the Operator of a Doosan Excavator, Location of Safety Labels, Summary of Safety Precautions for Lifting in Digging Mode, Unauthorized Modifications, Before Starting Engine, Machine Operation, Maintenance, Battery, Towing, Shipping and Transportation, Lifting with Sling) |
| Specifications | 51-78 | Specification for DX300LCA |
| General Maintenance | 79-116 | Standard Torques |
| Upper Structure | 117-224 | Cabin, Counterweight, Fuel Tank, Fuel Transfer Pump, Swing Bearing, Swing Reduction Gear |
| Lower Structure and Chassis | 225-256 | Track Assembly |
| Engine and Drive Train | 257-268 | Drive Coupling |
| Hydraulic System Overview & General Troubleshooting | 269-304 | General Notes, Working Components Operation, Pilot Pressure Adjustment, Pump Input Power Control, Flow Meter Testing, Swing System Troubleshooting |
| Accumulator, Center Joint & Cylinders | 305-356 | Accumulator Description, Center Joint Disassembly, Cylinder Theory of Operation, Cylinder Reassembly, Parts Lists |
| Hydraulic Motors (Swing & Travel) | 357-438 | Swing Motor Description, Swing Motor Troubleshooting, Travel Motor Operation Basics, Travel Motor Disassembly, Travel Motor Reassembly |
| Hydraulic Pumps (Axial Piston & Gear) | 439-502 | Axial Piston Pump Theory, Axial Piston Pump Troubleshooting, Gear Pump Disassembly, Gear Pump Reassembly |
| Electrical System | 657-780 | Electrical Supply System, Engine Starting Circuit, Charging System, Monitoring System, Electronic Hydraulic Control System (e-EPOS), Air Conditioner System |
| Attachments | 781-810 | Boom and Arm, Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Standard Torques | SP000813 | p. 5 |
| Axial Piston Pump | SP000068 | p. 6 |
| TORQUE VALUES FOR SPLIT FLANGES - 1/2" Flange Size, 5/16" Bolt Size | 15-18 ft lb | p. 111 |
| TORQUE VALUES FOR HOSE CLAMPS - Hydraulic System, Worm Drive - Under 44 mm (1-3/4 in) Open Diameter | 40-50 in lb | p. 110 |
| Fuel filter replacement | Loosen plug (1, Figure 23) on top of fuel filter head. | p. 155 |
| Pilot Pressure and Tolerance | 30 bar +10 bar (435 psi +145 psi) | p. 450 |
| Shipping Weight | 29.2 metric tons | p. 66 |
| Fuel Tank Capacity | 500 liters | p. 66 |
| Hydraulic System Capacity | 280 liters | p. 66 |
| Engine Power Output | 200 ps @ 1,900 rpm | p. 69 |
| Main Relief Pressure (normal operation) | 330 kg/cm3 | p. 72 |
| Swing Motor Output Torque | 85.1 kg•m | p. 368 |
Doosan DX225LC-DX520LC Series Common Problems This Manual Covers
Doosan DX300LC hydraulic pump grinding noise and vibration under load, boom lifts slowly
Check hydraulic oil level and condition; the system holds 280 liters per page 66. Test pilot pressure against the 30 bar plus 10 bar spec (435 psi plus 145 psi) on page 450. If grinding continues, suspect cavitation from a restricted suction line and work through the pump troubleshooting steps starting on page 439.
Manual Section: Hydraulic Pumps (Axial Piston & Gear) p. 439Swing motor slow rotation with abnormal pressure, E30 code flashing on the monitor
Pull the error code reference and confirm E30 reads swing motor pressure abnormal. Gauge the swing circuit at the motor ports, then compare performance against the 85.1 kg•m output torque spec on page 368. Inspect the make-up valve and brake release circuit; motor troubleshooting begins on page 357.
Manual Section: Hydraulic Motors (Swing & Travel) p. 357Hydraulic oil leaking from hose fittings and split flanges after long service hours
Clean each fitting, run the machine, and trace the fresh leak to its source. Retorque split flange bolts to the chart on page 111; a 1 inch flange with 3/8 inch bolts takes 27-35 ft lb. Tighten worm drive hose clamps under 44 mm to 40-50 in lb per page 110. Replace any hose with a cracked cover.
Manual Section: General Maintenance p. 111Hydraulic system overheating during heavy digging, oil temperature climbing into the red zone
Check oil level against the 280 liter system capacity and top up with clean oil. Blow debris out of the oil cooler fins with compressed air. Verify main relief pressure holds the 330 kg/cm2 setting listed on page 72; a relief valve stuck partially open dumps flow to tank and builds heat fast. Follow the oil temperature procedures on page 298.
Manual Section: Hydraulic System Overview & General Troubleshooting p. 298Machine pulls to one side when traveling, one track noticeably slower than the other
Swap the travel hoses side to side to isolate the motor from the control valve. Test relief valve cracking pressure on the slow side; spec is 330 kg/cm2 per page 410. Replace the relief cartridge if pressure runs low. Check the slow track for packed mud and correct tension before condemning the motor.
Manual Section: Hydraulic Motors (Swing & Travel) p. 410Frequently Asked Questions
How to reset Doosan DX300LCA error codes?
To reset error codes, navigate to the 'Failure Info' screen in the special menu. Select 'Delete Fail Log' and confirm with 'YES'. A 'Delete Completed' screen will appear for 3 seconds, and then the screen will move to the previous menu. p. 701
What are the torque specs for Doosan DX350LC hydraulic pump bolts?
For the DX350LC, the torque value for the main pump coupling bolts (Ta) is 44 - 49 kg•m (318 - 354 ft lb), and for the clamping screws (Tb) it is 20 - 22 kg•m (145 - 159 ft lb). These values are specified for the coupling part number 414-00040A or 414-00041A. p. 267
How to clear Doosan DX225LC service alarm code?
To clear service alarm codes, access the 'Failure Info' screen in the special menu. Select the 'Delete Fail Log' option and confirm by pressing 'YES'. A confirmation message will display for 3 seconds before returning to the previous menu. p. 701
What are the replacement specifications for the K5V140 hydraulic pump's cylinder and spherical bushing components?
For the K5V140 hydraulic pump, the recommended replacement values for worn parts include a clearance between the piston and cylinder bore of 0.043 / 0.070, a play between the piston and shoe caulking section of 0-0.1 / 0.3, a shoe thickness of 4.9 / 4.7, a free height of the cylinder spring of 41.1 / 40.3, and a combined height of the set plate and spherical bushing of 23.0 / 22.0. p. 456
What is the recommended hydraulic oil temperature for conducting excavator performance tests?
For excavator performance tests, the hydraulic oil should be warmed up to a standard operating temperature between 45° - 55°C (112° - 135°F) to ensure accurate results. p. 73
What format is this manual in?
Instant PDF download. You get the full 810-page searchable Shop Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print this manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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