Part of the Doosan Repair Manuals.
Hunting for a Doosan DX180LC shop manual PDF? You just found it: 808 pages of factory shop manual (OEM #950106-00303) serving five Doosan track excavators, the DX180LC, DX225LC, DX225NLC, DX235NLC, and DX255LC, in one download. Inside: full electrical schematics, hydraulic schematics, and a complete hydraulic troubleshooting section for main relief pressure, actuator speeds, and pilot pressure. You get step-by-step teardown and reassembly for the swing motor, TM40VD travel motor, main control valve, gear pump, and cylinders, plus standard torque tables and track assembly service. Set the main relief to 330 kg/cm2 (350 in pressure-up mode) and fill the hydraulic reservoir with 140 liters before testing. Your excavator is down; forum guesses won't lift it. Bookmarked with a full text layer, so you can search any spec, jump straight to the section, and start wrenching.
What's Inside This Doosan DX235NLC Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 7-54 | Track Excavator Safety |
| Specifications | 55-84 | Specification for DX235NLC |
| General Maintenance | 85-122 | Standard Torques |
| Upper Structure | 123-226 | Cabin, Counterweight, Fuel Tank, Fuel Transfer Pump, Swing Bearing, Swing Reduction Gear |
| Lower Structure and Chassis | 227-262 | Track Assembly |
| Engine and Drive Train | 263-274 | Drive Coupling |
| Hydraulic System Troubleshooting, Testing and Adjustment | 275-312 | Main Relief Pressure, Actuator Speeds, Pilot Pressure, Swing System Troubleshooting, Control Valve Troubleshooting |
| Accumulator | 313-320 | Accumulator Operation, Precharge Pressure, Specifications |
| Center Joint (Swivel) | 321-334 | Center Joint Inspection, Disassembly, Reassembly, Seal Replacement |
| Cylinders | 335-364 | Cylinder Theory of Operation, Disassembly, Reassembly, Piston Nut, Slipper Seal Jig |
| Swing Motor | 365-396 | Swing Motor Structure, Operational Principles, Disassembly, Reassembly, Maintenance Standards |
| Travel Motor | 397-456 | TM40VD Operation, Disassembly, Reassembly, Testing, Lubricating Oil |
| Gear Pump | 457-468 | Single Gear Pump Disassembly, Reassembly, Tightening Torque |
| Main Control Valve | 469-653 | Main Control Valve Operation, Disassembly, Reassembly, Relief Valve Maintenance, Antidrift Valve |
| Electrical System | 654-784 | Electrica System, Electrical Schematic |
| Attachments | 785-808 | Boom and Arm, Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main Relief Pressure (Normal) | 330 kg/cm2 | p. 77 |
| Main Relief Pressure (Pressure Up) | 350 kg/cm2 | p. 77 |
| Fuel Tank Capacity | 340 liters | p. 72 |
| Hydraulic Reservoir Capacity | 140 liters | p. 72 |
| Engine Power | 158 ps | p. 74 |
| Max Torque | 68 kg•m | p. 74 |
| Swing Reduction Gear Oil Capacity | 3.8 liters | p. 222 |
| R134a Gas Weight | 800 grams | p. 760 |
Doosan DX235NLC Common Problems This Manual Covers
Doosan DX235NLC loses digging power, slow cycle times, pump response irregular under load
Check main relief pressure before pulling the pump. Warm the hydraulic oil, install a gauge on the test port, and stall the bucket; the DX235NLC spec is 330 kg/cm2 normal and 350 kg/cm2 in pressure-up mode, listed on page 77. If pressure checks good, work through the troubleshooting procedures on page 307 to isolate internal leakage.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 307Hydraulic oil foamy and milky, pump whines on startup, functions shudder until oil warms
Check the reservoir level first; low oil lets the pump suck air. The DX235NLC reservoir holds 140 liters, capacity listed on page 72, so fill to the sight gauge with clean oil. Inspect suction line clamps and pump inlet fittings for air leaks, then replace the return filter. If foaming continues, run the cavitation checks on page 307.
Manual Section: Hydraulic System Troubleshooting, Testing and Adjustment p. 307Swing reduction gear growling, upper structure rotation jerky, gearbox housing hot to the touch
Drain the swing reduction gear and inspect the old oil for metal flake before condemning parts. Refill with 3.8 liters of gear oil on the DX235NLC, capacity shown on page 222. If the growl remains after fresh oil, check the no-rotation, leakage, and overheat causes in the Swing Reduction Gear Troubleshooting chart, then pull the motor.
Manual Section: Upper Structure p. 222Cab air conditioner blows warm, compressor clutch cycles on and off rapidly in hot weather
Test system pressures with a manifold gauge set before adding refrigerant. Rapid clutch cycling usually means low charge from a slow leak; repair the leak, evacuate the system, and recharge with 800 grams of R134a on the DX235NLC, spec on page 760. Clean packed dust from the condenser fins and verify compressor compression per the troubleshooting chart.
Manual Section: Air Conditioner Troubleshooting p. 760Frequently Asked Questions
How do I reset the filter or oil service interval information on the Doosan DX235NLC?
To reset the operating hours for filters and oils, navigate to the 'Filter/Oil Info' mode in the main menu. After changing the filter and oil, you can reset the operating hour counter to easily track the time until the next service interval. p. 690
How do I delete past failure logs on the Doosan DX235NLC monitor?
To delete past failure logs, access the 'Special Menu' by pressing the Enter and Escape buttons simultaneously for more than 3 seconds. Navigate to 'Failure Information', select 'Delete Fail Log', and press the 'YES' button when prompted. You will need to enter the correct password to complete the deletion. p. 709
What is the fuel tank capacity for the Doosan DX235NLC?
The fuel tank capacity for the DX235NLC is 340 liters (89.8 U.S. gallons). p. 155
What is the tightening torque for the main relief valve on the DX235NLC?
The tightening torque for the main relief valve is 7.95 - 8.97 kg•m (58 - 65 ft lb). p. 536
What is the recommended gear oil quantity for the travel motor case?
The recommended quantity of gear oil for the travel motor case is 1.2 liters. p. 412
What format is this Doosan DX180–DX520 Series manual in?
A 808-page Shop Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Am I free to print this Doosan DX180–DX520 Series Shop Manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
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