Part of the Doosan Repair Manuals.
Need factory-level repair data for your Doosan DX235LCR hydraulic excavator? This 784-page Doosan DX235LCR shop manual PDF (OEM #950106-00081E) covers the whole machine, from swing bearing to travel motor. Inside: the factory hydraulic schematic, full electrical schematics spanning the starting, charging, and preheating circuits, plus step-by-step teardown and reassembly procedures for the main pump, main control valve, swing device, and cylinders. You also get pump regulator adjustment, pilot pressure testing, and a hydraulic troubleshooting section built for real diagnosis, not guesswork. The fuel tank holds 320 liters. Set your 1/2-inch split flange bolts at 15 to 18 ft lb and pull the 1-inch flanges to 27 to 35. No more chasing electrical gremlins with a test light and a hunch. Bookmarked with a live text layer; open it on your tablet, find the spec, and get the excavator digging again.
What's Inside This Doosan DX235LCR Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7-54 | Track Excavator Safety |
| Specifications | 55-82 | Specification for DX235LCR |
| General Maintenance | 83-120 | Standard Torques |
| Upper Structure | 121-176 | Cabin, Counterweight, Fuel Tank, Fuel Transfer Pump, Swing Bearing |
| Lower Structure andChassis | 177-212 | - |
| Engine and Drive Train | 213-226 | Drive Coupling |
| Hydraulic System Troubleshooting, Testing and Adjustment | 227-262 | Hydraulic Schematic, Operation of Working Components, Pilot Pressure, Power Mode Valve, Pressure Up Valve, Pump Regulator Adjustment |
| Accumulator | 263-270 | Accumulator General Description, Precharge Pressure, Specifications |
| Center Joint (Swivel) | 271-284 | Center Joint Inspection, Testing, Disassembly, Reassembly |
| Cylinders | 285-316 | Cylinder Theory of Operation, Disassembly, Reassembly, Special Tools, Piston Nut, Slipper Seal Jig |
| Swing Device | 317-368 | Swing Device Specifications, Motor Section Construction, Reduction Gear Section, Brake Part, Maintenance Standards |
| Travel Motor | 369-426 | TM40VD Operation Manual, Travel Motor Disassembly, Reassembly, Testing, List of Seals |
| Main Pump and PTO | 427-476 | General Repair Guidelines, Disassembly, Assembly, Tightening Torques, Gear Pump Sealing |
| Gear Pump and Main Control Valve | 477-638 | Single Gear Pump, Main Control Valve Disassembly, Main Relief Valve, Overload Relief Valve, Antidrift Valve |
| Electrical System | 639-762 | Electrical Supply System, Engine Starting Circuit, Engine Preheating System, Charging System, Monitoring System, Air Conditioner System |
| Attachments | 763-784 | Boom and Arm, Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Split Flange 1/2" Bolt Torque | 15 - 18 ft lb | p. 115 |
| Split Flange 3/4" Bolt Torque | 22 - 27 ft lb | p. 115 |
| "T" Bolt Hose Clamp Torque (Radiator, Air Cleaner, Boots, Etc.) | 59 - 63 in lb | p. 114 |
| Worm Drive Under 44 mm Hose Clamp Torque (Radiator, Air Cleaner, Boots, Etc.) | 20 - 30 in lb | p. 114 |
| Fuel tank capacity | 320 liters (84.5 U.S. gal) | p. 151 |
| Bolt torque for fuel filter plug | 27 kg•m (200 ft lb) | p. 157 |
| Hydraulic reservoir return line and pilot circuit filter rating | 10 micron | p. 236 |
| Reservoir intake strainer rating | 80 mesh, 177 micron | p. 236 |
| Boom operating circuit overload relief valve setting | 380 kg/cm2 (5,405 psi) | p. 237 |
| Boom up secondary pilot pressure | 7 - 9 kg/cm2 (100 - 130 psi) | p. 237 |
| Hydraulic system operating temperature | 50°C (122°F) | p. 236 |
| Hydraulic Oil Temperature Distribution Under 30°C | 87°F | p. 692 |
Doosan DX235LCR Common Problems This Manual Covers
Doosan DX235LCR boom and arm move slowly, hydraulic pressure drops under load
Test main relief pressure at cylinder stall in power mode; it should hold 350 to 355 bar (5,075 to 5,149 psi) per the chart on page 246. If pressure reads low, replace the 10 micron return line filter, inspect the 80 mesh intake strainer, then perform the pump regulator adjustment procedure.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 246Engine cranks slowly or won't start in cold weather, glow plug light stays off
Check the engine preheating circuit in the Electrical System section starting on page 639; test each glow plug for continuity and replace failed units. Drain water from the fuel filter and replace the element if contaminated, torquing the fuel filter plug bolt to 27 kg•m (200 ft lb) per page 157.
Manual Section: Electrical System p. 639Engine or hydraulic oil temperature gauge climbs into red zone during normal digging
Check coolant level and clean debris from the radiator fins with compressed air. Tighten worm drive hose clamps over 44 mm to 40 to 50 in lb per page 114. Normal hydraulic oil temperature is 50°C (122°F) per page 236; if the monitor shows readings above the 86 to 95°C band, clean the hydraulic oil cooler core.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 236Joystick response lags and all hydraulic functions feel weak at full engine throttle
Measure pilot pressure at the pump outlet; spec is 40 ± 5 bar (580 ± 73 psi) per page 244. If low, replace the 10 micron pilot circuit filter listed on page 236. Test the solenoid valve assembly for sticking spools and verify joystick full-stroke output pressure matches the same 40 bar spec.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 244Machine tracks pull to one side or travel feels weak climbing grades
Check gear oil level in each travel device; the travel motor reduction gear holds 3.3 liters per page 386. Drain and refill if the oil is milky or contaminated. Test travel motor operation using the disassembly and testing procedures in the Travel Motor section starting on page 369, and inspect center joint seals for leakage.
Manual Section: Travel Motor p. 386Frequently Asked Questions
How do I reset the failure log on the Doosan DX235LCR?
To delete the memorized record of past failures, navigate to the 'Failure Info' screen in the special menu. Select 'Delete Fail Log' and press the Enter button. You will be prompted to enter a password; input the password using the No. 1-8 switches to confirm the deletion. p. 684
What is the torque specification for the mounting nuts on the cabin?
The mounting nut torque for the cabin is 21 kg•m (205 Nm, 150 ft lb). p. 132
What is the fuel tank capacity for the DX235LCR?
The fuel tank capacity for the DX235LCR is 320 liters (84.5 U.S. gal). p. 151
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. 386
What is the tightening torque for the main relief valve on the main control valve?
The tightening torque for the main relief valve is 7.95 - 8.97 kg•m (58 - 65 ft lb). p. 549
What format is this Doosan DX235LCR manual in?
A 784-page Shop Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
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