Part of the Doosan Repair Manuals.
This is the factory shop manual for the Doosan DX235LCR-5, publication 950106-01109E, covering 2014-2019 machines. If you bought this excavator, you bought it for the tail - 1,680 mm swing radius and 1,060 mm counterweight clearance let it work a single lane without eating the next one. The manual covers the whole machine: engine, hydraulic system, upper structure, lower structure and chassis, front group, electrical system, plus full schematics. This is a -5 generation Tier-4 era machine with electronic engine control, so the electrical section actually matters here - it is not three pages of fuses. You also get the numbers a working shop needs: component weights for rigging, pressures, capacities, and step-by-step teardown for pumps, cylinders, and travel gear.
What's Inside This Doosan DX235LCR-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7-74 | Safety Precautions, Decals, Lifting and Towing |
| Specifications | 75-108 | Machine Specifications, Working Ranges, Digging Forces, Component Weights, Capacities |
| General Maintenance | 109-146 | Service Intervals, Fluids and Lubricants, Filters, Standard Torques |
| Engine | 147-328 | Engine Removal and Overhaul, Cooling, Fuel System, Air Intake, Aftertreatment |
| Upper Structure | 329-806 | Cab, Counterweight, Swing Bearing and Swing Motor, Tanks, Main Pump Mounting |
| Lower Structure and Chassis | 807-974 | Track Frame, Travel Motor, Idler, Rollers, Track Chain |
| Front | 975-1030 | Boom, Arm, Bucket and Linkage Service |
| Hydraulic System | 1031-1112 | Main Pump, Control Valve, Cylinders, Pressure Tests and Adjustments, Hydraulic Schematics |
| Electrical System | 1113-1282 | Wiring, Sensors, Switches, Gauges, Starting and Charging, Electrical Schematics |
| Options | 1283-1356 | Optional Attachment Hydraulics and Equipment |
| Schematic | 1357-1362 | Hydraulic and Electrical Schematic Sheets |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tail Swing Radius | 1,680 mm | p. 86 |
| Counterweight Clearance | 1,060 mm | p. 86 |
| Shoe Width | 600 mm | p. 86 |
| Min. Swing Radius | 2,310 mm | p. 89 |
| Shipping Weight | 23.9 tons | p. 92 |
| Shipping Weight with Optional Track Shoes | Add 284 kg | p. 92 |
| Major Component Weight (Standard Boom) | 1,482 kg | p. 92 |
| Major Component Weight (Arm) | 599 kg | p. 92 |
| Major Component Weight (Boom Cylinders) | 213 kg each | p. 92 |
| Major Component Weight (Arm Cylinder) | 237 kg | p. 92 |
| Major Component Weight (Bucket Cylinder) | 145 kg | p. 92 |
| Major Component Weight (Counterweight) | 6,450 kg | p. 92 |
| Major Component Weight (Upper Structure) | 5,920 kg | p. 92 |
| Digging Force (Bucket Cylinder) | 16,046 kg | p. 92 |
Doosan DX235LCR-5 Common Problems This Manual Covers
Engine fails to start or cuts out unexpectedly under load, usually traced to fuel contamination or injection pump trouble.
Work through the Engine section's fuel system diagnostics before condemning the pump: check filter condition, verify supply pressure, and inspect for water and debris in the tank. The manual gives the test sequence for the injection components and the specs to judge them against, plus sensor checks via the Electrical System section since electronic control can mimic fuel starvation.
Manual Section: Engine p. 147Hydraulic system loses pressure, boom or arm drifts down, or breakout force falls below the rated 16,046 kg at the bucket.
The Hydraulic System section covers pressure testing at the pump, main control valve inspection, relief valve adjustment, and full cylinder reseal procedures. Test in the order the manual gives - pump first, then valve, then cylinders - so you replace the part that failed, not the three parts upstream of it. System holds 230 L total, 190 L in the reservoir, so plan your oil order before opening it up.
Manual Section: Hydraulic System p. 1031Engine overheats even with a clean radiator, pointing at the water pump, thermostat, or clogged internal coolant passages.
Work the cooling circuit in the Engine section: test and replace the thermostat, inspect and pull the water pump, then flush the block by the factory procedure. If the radiator runs clean while the engine still runs hot, the fault sits inside the circuit, and the temperature and flow checks tell you which part to condemn before you buy a radiator the machine does not need.
Manual Section: Engine p. 147Track tension will not hold or the track walks off the frame, typically worn rollers, damaged idlers, or stretched chain links.
The Lower Structure and Chassis section covers track adjuster service, roller and idler removal, measurement specs for wear limits, and chain replacement on the 600 mm shoes. Measure the undercarriage against the wear tables before buying parts - a thrown track is often a worn idler flange or seized adjuster, not the chain itself, and the difference is thousands of dollars.
Manual Section: Lower Structure and Chassis p. 807Frequently Asked Questions
My boom drifts down when parked and digging power feels weak. Does this manual cover diagnosing that?
Yes, and this is the most common reason people buy it. The Hydraulic System section walks through pressure testing at the pump and main control valve, relief valve settings, and cylinder teardown for reseal. Drift usually comes down to cylinder piston seals or a leaking holding valve, and the manual gives you the test sequence to tell which before you tear anything apart. For reference, a healthy machine puts out 16,046 kg bucket digging force.
The engine cuts out under load or is hard to start. Is the fuel system covered in enough depth to actually fix it?
The Engine section covers the complete fuel system on this Tier-4 era electronically controlled diesel: filters, supply pump, injection components, and the troubleshooting logic for no-start and dies-under-load conditions. On these machines the usual culprit is fuel contamination working its way past neglected filters, so start there. The Electrical System section backs it up with sensor and wiring checks, since a bad signal can look exactly like a fuel problem.
How do I reset the maintenance reminder and deal with warning lights on the monitor?
The Electrical System section documents the instrument panel and monitor, including how to step through the service menus, read active warnings, and clear the maintenance interval reminder after you have done the work. I will not quote you specific fault codes here - the manual has the actual code tables and the diagnostic steps for each, which beats guessing off a forum post.
I need to pull the counterweight and split the machine. Are the component weights in here for rigging?
Yes. The Specifications section lists what you are actually slinging: counterweight 6,450 kg, upper structure 5,920 kg, everything below the swing bearing 7,718 kg, standard boom 1,482 kg, arm 599 kg, and the cylinders individually. Shipping weight is 23.9 tons. Do not eyeball a 6.5 ton counterweight - use the numbers and rig accordingly. The Upper Structure section covers the removal procedures themselves. p. 86
Which machines does this manual fit, and does it cover the reduced tail swing configuration?
It covers DX235LCR-5 machines built 2014 through 2019. The LCR reduced tail swing layout is not an option package, it is the machine - 1,680 mm tail swing radius, 2,310 mm minimum front swing radius, 600 mm standard shoes - and the manual is written for exactly this configuration. Optional equipment like alternate shoe widths is covered in the Options section. p. 86
Reviews
There are no reviews yet.