Doosan DX235LCR 2018 Operation & Maintenance Manual
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Doosan DX235LCR 2018 Operation & Maintenance Manual

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EXCAVATOR
Operation &
Maintenance
Manual
DX235LCR
Serial Number 5001 and Up
950106-00082DE
September 2018

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Summary of Contents for Doosan DX235LCR 2018

  • Page 1 EXCAVATOR Operation & Maintenance Manual DX235LCR Serial Number 5001 and Up 950106-00082DE September 2018...
  • Page 3 Operation & Maintenance Manual DX235LCR EXCAVATOR Serial Number 5001 and Up DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the 950106-00082DE world. September 2018 © Doosan Infracore 2018...

  • Page 5: Table Of Contents

    Table of Contents EC Declaration of Conformity ............0-1 Safety ..................1-1 To the Operator of a DOOSAN Excavator ......... 1-1 Safety Decals..................1-4 Visibility Information ................. 1-18 Summary of Safety Precautions for Lifting in Digging Mode.... 1-20 Unauthorized Modifications.............. 1-21 General Hazard Information.............
  • Page 6 Miscellaneous Electrical Devices............. 2-53 Seat Adjustment................2-55 Ceiling Cover ................... 2-59 Front Windows ................. 2-60 Door Side Latch ................2-62 Cabin Storage Compartments ............2-63 Ashtray..................... 2-63 Sun Visor ..................2-64 Hanger ..................... 2-64 Cup Holder..................2-64 Emergency Glass Breaking Tool ............. 2-65 Miscellaneous Access Covers and Doors........
  • Page 7 Maintenance Intervals..............4-13 10 Hour / Daily Service ..............4-15 50 Hour / Weekly Service ..............4-27 250 Hour / Monthly Service.............. 4-30 500 Hour / 3 Month Service ............. 4-36 1,000 Hour / 6 Month Service ............4-46 2,000 Hour / Yearly Service ............. 4-56 4,000 Hour / Biennial Service ............
  • Page 8 Table of Contents DX235LCR...

  • Page 9: Ec Declaration Of Conformity

    EC DECLARATION OF CONFORMITY Doosan Benelux SA, Drève Richelle 167, 1410 Waterloo, (Belgium),  as authorized representative in the European Community of Doosan Infracore Co., Ltd. (Korea),  certifies that the construction equipment machinery. Type of Machine : HYDRAULIC CRAWLER EXCAVATOR Manufacturer : Doosan Infracore Co., Ltd., 489, Injung-ro, Dong-gu, Incheon, Korea...
  • Page 10 0-2 DX235LCR...

  • Page 11: Safety

    Safety TO THE OPERATOR OF A DOOSAN EXCAVATOR DANGER AVOID DEATH Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
  • Page 12 In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been sent. If this machine has been purchased in another...
  • Page 13 Learn Signal Words Used with Safety Alert Symbol The words "CAUTION", "WARNING", and "DANGER" used throughout this manual and on decals on the machine indicate degree of risk of hazards or unsafe practices. All three degrees of risk indicate that safety is involved. Observe precautions indicated whenever you see the Safety Alert "Triangle", no matter which signal word appears next to "Exclamation Point"...

  • Page 14: Safety Decals

    SAFETY DECALS Safety decals are attached to the machine to alert the operator maintenance person about potential hazards, consequences of potential injury, and instructions and/or actions required to avoid the hazard. The location of the safety decals and the description of the decals are reviewed in the following section.
  • Page 15 Safety Decals Without Text (No-Text) Vertical Configuration Safety decals without text consist of a safety sign and safety information panel. The safety sign panel is located at the top or left side and the safety information panel is located at the bottom or right side of the decal depending on its configuration.
  • Page 16 Information and Location for Safety Decals EX1402438 Figure 2 Safety DX235LCR...
  • Page 17 Information and Location for Safety Decals (Continued) 7, 8 EX1402439 Figure 3 Safety DX235LCR...
  • Page 18 General Hazard (950205-03804) EX1301176 WARNING AVOID DEATH OR SERIOUS INJURY • Never use excavator without instructions. • Read Operation & Maintenance Manual before operation. • Sound the horn to alert bystanders before operating. • Always fasten your seat belt. • Explosion or electrocution can occur if machine contacts utility lines or pipes.
  • Page 19 Warning Tag - "Do Not Operate" (950205-03802) WARNING AVOID DEATH OR SERIOUS INJURY • Stop engine and remove key. • Attach "DO NOT OPERATE" warning tag to the controls before servicing the machine. EX1301177 • Do not operate when performing inspection or maintenance.
  • Page 20 Rotating Fan (950205-03788) WARNING CONTACT WITH ROTATING FAN CAN CAUSE DEATH OR SERIOUS INJURY Keep away from fan and rotating parts. Stop engine 950205-03788 before servicing. EX1301182 Battery Explosion (950205-03785) WARNING AVOID DEATH OR SERIOUS INJURY • Read and follow instructions in Operation & Maintenance Manual for battery maintenance.
  • Page 21 Flying Debris or Objects (950205-03866) WARNING HIGH-PRESSURE GREASE CAN CAUSE DEATH OR SERIOUS INJURY EX1301185 • Track adjusting systems use grease under high- pressure which can penetrate body if improperly serviced. • NEVER LOOSEN track tension grease valve more than one complete turn from the fully tightened position.
  • Page 22 12. Fall Hazard (950205-03783) WARNING AVOID DEATH OR SERIOUS INJURY Do not step in this area. EX1301188 13. Hot Surface (950205-03777) WARNING HOT SURFACE CAN CAUSE SERIOUS BURNS • Do not touch hot surface. • Allow to cool before servicing. EX1301189 14.
  • Page 23 15. ISO Control Pattern (950205-03860) WARNING AVOID INJURY OR DEATH Read and understand the Operation & Maintenance Manual for more information. Refer to "Operating Instructions" section of this manual details regarding work levers (joysticks) control functions. BHL Control Pattern (US Only) (950205-03868) WARNING AVOID INJURY OR DEATH Read and understand the Operation &...
  • Page 24 17. Ultra Low Sulfur Diesel Fuel (Optional)  (950205-03863, 950205-03864) ULTRA LOW SULFUR DIESEL FUEL ONLY IMPORTANT Only use Ultra Low Sulfur Diesel (ULSD) fuel with this machine. EX1301196 EX1301194 18. ROPS Warning (Optional) (950205-03861) WARNING AVOID DEATH OR SERIOUS INJURY •...
  • Page 25 19. Falling Object (Optional) (950205-03786) WARNING UNSUPPORTED DOOR CAN FALL CAUSING DEATH OR SERIOUS INJURY • To open door: Hold door firmly. Lift door slowly until locking device engages. • To close door: EX1301198 Hold door firmly. Press locking device to disengage. Lower door slowly.
  • Page 26 20. Hydraulic Oil Check (Optional)  (950205-06281, 950205-03965, 950205-06282) IMPORTANT INCORRECT OIL LEVEL OR INCORRECT FLUID CAN CAUSE HYDRAULIC SYSTEM DAMAGE Place the excavator with the boom and arm fully extended with the attachment on the ground before checking hydraulic fluid level. Use hydraulic oil which is suitable for machine.
  • Page 27 21. Hydraulic Breaker (Optional) (950205-03964) IMPORTANT AVOID HYDRAULIC SYSTEM DAMAGE adjust breaker impact, Operation & Maintenance Manual for additional instructions. EX1301200 22. Lift/Tie down (Optional) (950205-03815) Identifies lift point and tie down point location. 950205-03815 EX1301201 23. Tie down (Optional) (950205-03816) Identifies tie down point location.

  • Page 28: Visibility Information

    VISIBILITY INFORMATION A rear view camera and mirrors ensure that visibility around the machine, from the operator's seat, meets the latest ISO standards for the region or marketplace that the machine is sold into. NOTE: These devices may vary from one region to another, depending upon local and regional regulations.
  • Page 29 Inspect equipment and immediately report if there are problems with the visual aids. If machine cannot be fixed immediately, DO NOT use the machine. Contact your local DOOSAN distributor as soon as possible and ask for repairs. Guidelines •...

  • Page 30: Summary Of Safety Precautions For Lifting In Digging Mode

    SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING IN DIGGING MODE DANGER AVOID DEATH Unsafe use of the excavator while making rated lifts could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property. Do not let anyone operate the machine unless they've been properly trained and understand the information in the Operation and Maintenance Manual.

  • Page 31: Unauthorized Modifications

    UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner will be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking...
  • Page 32 Safety Features Be sure that all guards and covers are installed in their proper position. Have guards and covers repaired immediately if damaged. Be sure that you understand the method of use of safety features such as safety lock lever and the seat belt, and use them properly.
  • Page 33 Clothing and Personal Protective Items Secure long hair, and avoid loose clothing and jewelry. These items have the tendency to catch on controls or protrude into parts and cause serious injury or death. Do not wear oily clothes. They are flammable. Full eye protection, a hard hat, safety shoes and gloves may be required at the work site.
  • Page 34 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a DOOSAN genuine part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.
  • Page 35 Mounting and Dismounting Before getting on or off the machine, if there is any oil, grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts. Never jump on or off the machine.
  • Page 36 Precautions When Handling Fluids at High Temperature Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at highest temperatures and the radiator and hydraulic tank are still under pressure. Attempting to remove cap, drain the oil or coolant, or replacing the filters may lead to serious burns.
  • Page 37 Injury from Work Equipment Do not enter or put your hand, arm or any other part of your body between movable parts, such as between the work equipment and cylinders, or between the machine and work equipment. If the control levers are operated, the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury.
  • Page 38 If any glass on the machine is broken, replace it with new glass immediately. Attachment Precautions Option kits are available through your dealer. Contact DOOSAN for information on available one-way (single-acting) and two-way (double-acting) piping/valving/auxiliary control kits. Because DOOSAN cannot anticipate, identify or test all the attachments...
  • Page 39 When carrying out disassembly or maintenance of the accumulator, or when disposing of the accumulator, the charged gas must be properly released. Contact your DOOSAN distributor. • Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under pressure can penetrate the skin and cause serious injuries.

  • Page 40: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make sure the ground surface is as hard and horizontal as possible before carrying out operations.
  • Page 41 Remember that soil after heavy rain, blasting or after earthquakes, is weakened. Newly laid earth and the soil near ditches is typically loose. It can collapse under the weight of vibration of your machine and cause your machine to tip over. Install the head guard (FOPS) if working in areas where there is a danger of falling rocks.
  • Page 42 Engine Starting Walk around your machine before getting in the operator's cabin. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated.
  • Page 43 Before Operating Machine If checks are not carried out properly after starting the engine, it can result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions.
  • Page 44 If original color of webbing in these areas is extremely faded and/or webbing is packed with dirt, webbing strength may be reduced. NOTE: Contact your DOOSAN distributor for seat belt system replacement parts. WARNING AVOID DEATH OR SERIOUS INJURY...

  • Page 45: Machine Operation

    MACHINE OPERATION When Swinging or Changing Direction of Travel Before operating the machine or the work equipment, always observe the following precautions to prevent serious injury or death. • Start and operate the machine only while seated. • When changing travel direction from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing travel direction.
  • Page 46 Travel Precautions Travel Posture Never turn the starting switch to "O" (OFF) position when traveling. It is dangerous if the engine stops while the machine is traveling. It will be impossible to operate the steering. Attachment control levers should not be operated while traveling.
  • Page 47 Traveling on Slopes Never jump onto a machine that is running away to stop it. There is a danger of serious injury. Traveling on slopes could result in the machine tipping over or slipping. On hills, banks or slopes, carry the bucket approximately 20 - 30 cm (8 - 12 in) above the ground.
  • Page 48 Prohibited Operations Do not dig the work face under an overhang. This can cause the overhang to collapse and fall on top of the machine. FG015875 Figure 23 Do not carry out deep digging under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
  • Page 49 Precautions for Operation Be careful not to mistakenly travel too close to the edge of a cliff. Use the machine only for its main purpose. Using it for other purposes will cause failures. To ensure a good view, always do the following: •...
  • Page 50 AVOID DEATH OR SERIOUS INJURY Never modify the operator cabin by welding, grinding, drilling holes or adding attachments unless instructed by DOOSAN. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and result in serious injury or death.
  • Page 51 Protecting Cabin from Falling Object (Optional) In a work site where falling objects or flying objects are expected, be sure to install adequate protective devices for covering the cabin. When using a breaker, be sure to install the front window protection guard (1, Figure 29).
  • Page 52 Operations on Slopes When working on slopes. there is a danger that the machine may lose its balance and turn over, when swinging, or when work equipment is operated. Always carry out these operations carefully. Do not swing the work equipment from the uphill side to the downhill side when the bucket is loaded.

  • Page 53: Maintenance

    OSHA certified lockout device and a length of chain or cable to keep the safety lever in the fully lowered, nonnative position. Warning tags, for controls are available from DOOSAN distributors. EX1301177 Figure 34...
  • Page 54 Proper Tools Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. There is a danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness. HDO1037L Figure 36 Use of Lighting...
  • Page 55 Burn Prevention When checking the radiator coolant level, stop engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
  • Page 56 Welding Repairs IMPORTANT When disconnecting or connecting connectors between ECU and engine, or connector between ECU and the machine, always disconnect the battery to prevent damage to ECU. If you do not follow this procedure, the ECU will be damaged and/or the engine will not operate properly. When performing welding repairs, perform welding in a properly equipped place.
  • Page 57 Attachment Removal DANGER AVOID DEATH DOOSAN warns any user, that removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
  • Page 58 Precautions for Removal, Installation, and Storage of Attachments Before starting removal and installation of attachments, decide on the team leader. Do not allow anyone except the authorized workers close to the machine or attachment. Place attachments that have been removed from the machine in a safe place so they do not fall.
  • Page 59 Prevention of Crushing and Cutting You should always have at least two people working together if the engine must be run during service. One person needs to remain in the operator's seat, ready to work the controls or stop the machine and shut off the engine. Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.
  • Page 60 If necessary depending on the type of failure, please contact your DOOSAN distributor for repairs. Precautions with High-pressure Lines, Tubes and Hoses When inspecting or replacing high-pressure piping or hoses, check to verify that pressure has been released from the circuit.
  • Page 61 Waste Materials Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities. To prevent pollution of the environment, always do the following: •...

  • Page 62: Battery

    BATTERY Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following: • Do not smoke or bring any flame near the battery. •...
  • Page 63 Boost Starting or Charging Engine Batteries If any mistake is made in the method of connecting the booster cables, it can cause an explosion or fire. Always do the following: • Turn off all electrical equipment before connecting leads to the battery.

  • Page 64: Towing

    • If the engine on the problem machine will not start or there is a failure in the brake system. always contact your DOOSAN distributor. • Never go between the towing machine and the towed Towing Wire machine during the towing operation.

  • Page 65: Shipping And Transportation

    SHIPPING AND TRANSPORTATION Obey State and Local Over-the-Road Regulations Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.

  • Page 66: Excavator Rated Lift Capacity Tables

    EXCAVATOR RATED LIFT CAPACITY TABLES WARNING AVOID DEATH OR SERIOUS INJURY Let everybody be away from the boom cylinder. While lifting operation, boom, arm, bucket hoses might burst and then high-pressure oil will be ejected at high-speed. If that failure mode takes place, handling weight or front structure might fall by its gravity to the ground to cause fatal injury to the person.
  • Page 67 • Keep the bucket hook point directly over the load. Tag lines on opposite sides of the load can help maintain greater stability against side loads and wind gusts. Avoid traveling with a suspended load. Before swinging (or if required, traveling), bring the load into an arm position (radius and height) that has a safer weight capacity rating and adequate movement clearance.
  • Page 68 Standard Track Width 2.99 m 9 10 Track Boom 18 8 SAE 0.92 m (CECE 0.81 m Bucket 600 mm (24 ) Shoe : 6,480 kg (14,286 Ib) Counter Weight : 1,000 kg (1,000 Ib) UNIT : Rating Over Front : Rating Over Side or 360 degree FG015898 Figure 54...
  • Page 69 Feet A (ft) Max. Reach A (ft) B (ft) *11.95 *11.95 *8.50 *8.50 @19.29 *12.73 *12.73 *12.13 9.89 *8.14 7.48 @23.20 *19.97 *19.97 *15.63 15.46 *13.54 9.45 *9.58 6.29 *8.31 6.04 @25.53 *31.98 27.23 *19.96 14.05 15.25 8.83 10.48 6.02 *8.91 5.31 @26.74...
  • Page 70 Option: Boom 5.7 m, Arm 2.4 m Track Width 2.99 m 9 10 Track Boom 18 8 SAE 1.05 m (CECE 0.92 m Bucket 600 mm (24 ) Shoe : 6,480 kg (14,286 Ib) Counter Weight : 1,000 kg (1,000 Ib) UNIT : Rating Over Front : Rating Over Side or 360 degree...
  • Page 71 Feet A (ft) Max. Reach A (ft) B (ft) *13.84 *13.84 *11.66 *11.66 @17.25 *14.47 *14.47 *13.60 9.73 *11.15 8.49 @21.53 *23.85 *23.85 *17.40 15.13 *14.67 9.34 *11.43 6.73 @24.04 *21.63 13.78 15.16 8.76 10.47 6.02 10.24 5.88 @25.33 23.39 12.68 14.55 8.22...
  • Page 72 Option: Boom 5.7 m, Arm 2.9 m, Shoe 800 mm Track Width 3.19 m 10 6 Track Boom 18 8 SAE 0.92 m (CECE 0.81 m Bucket 800 mm (32 ) Shoe : 6,480 kg (14,286 Ib) Counter Weight : 1,000 kg (1,000 Ib) UNIT : Rating Over Front : Rating Over Side or 360 degree...
  • Page 73 Feet A (ft) Max. Reach A (ft) B (ft) *11.95 *11.95 *8.50 *8.50 @19.29 *12.73 *12.73 *12.13 10.12 *8.14 7.66 @23.20 *19.97 *19.97 *15.63 *15.63 *13.54 9.68 *9.58 6.47 *8.31 6.21 @25.53 *31.98 27.84 *19.96 14.38 *15.50 9.06 10.77 6.19 *8.91 5.47 @26.74...
  • Page 74 Option: Boom 5.7 m, Arm 2.4 m, Shoe 800 mm Track Width 2.19 m 10 6 Track Boom 18 8 7 11 SAE 1.05 m (CECE 0.92 m Bucket 800 mm (32 ) Shoe : 6,480 kg (14,286 Ib) Counter Weight : 1,000 kg (1,000 Ib) UNIT : Rating Over Front...
  • Page 75 Feet A (ft) Max. Reach A (ft) B (ft) *13.84 *13.84 *11.66 *11.66 @17.25 *14.47 *14.47 *13.60 9.96 *11.15 8.70 @21.53 *23.85 *23.85 *17.40 15.46 *14.67 9.57 *11.43 6.91 @24.04 *21.63 14.11 15.54 8.99 10.76 6.19 10.52 6.05 @25.33 23.99 13.01 14.93 8.45...
  • Page 76 Safety DX235LCR 1-66...

  • Page 77: Operating Controls

    Operating Controls The "Operating Controls" section presented here consists of the following groups: "Component Locations" on page 2-2 "Operator's Area" on page 2-4 "Operational Controls and Panels" on page 2-6 "Instrument Panel" on page 2-19 "Multifunction Gauge Graphic Information" page 2-25 "Mode Selector Buttons"...

  • Page 78: Component Locations

    COMPONENT LOCATIONS 9 10 15 16 17 FG016014 Figure 1 Operating Controls DX235LCR...
  • Page 79 Reference Reference Description Description Number Number Counterweight Boom Muffler Fuel Tank Bucket Cylinder Fuel Tank Fill Cap Guide Link Engine Bonnet Push Link Hydraulic Oil Tank Bucket Engine Tooth Point Swing Motor Side Cutter Radiator and Oil Cooler Idler Center Joint Track Adjuster Swing Bearing Control Valves...

  • Page 80: Operator's Area

    OPERATOR'S AREA FG015902 Figure 2 Operating Controls DX235LCR...
  • Page 81 Reference Reference Description Description Number Number Instrument Panel Seat (See page 2-19) (See page 2-55) Cigarette Lighter Storage Compartment (See page 2-15) (See page 2-63) Ashtray Heater and Air Conditioner Unit (See page 2-63) Stereo Travel Levers (See page 2-52) (See page 3-16) Fuse Box Right-hand Work Lever (Joystick)

  • Page 82: Operational Controls And Panels

    OPERATIONAL CONTROLS AND PANELS FG015903 Figure 3 Operating Controls DX235LCR...
  • Page 83 Reference Reference Description Description Number Number Starter Switch Cigarette Lighter Engine Speed Control Dial Power Socket For 12v Quick Coupler Switch (Optional) Travel/Swing Alarm Switch (Optional) Auxiliary Mode Switch Seat Warmer Switch (Optional) Engine Emergency Stop Switch Horn Button Audio Control Panel Rotating Switch Travel Speed Selector Switch Breaker/Booster Switch...
  • Page 84 1. Starter Switch A three-position starter switch is used to start or stop engine for equipment operation. Turning switch to this position turns engine "OFF" with its electrical system. In this position engine is "OFF" but interior cabin light and fuel tank transfer pump (if equipped) are functional.
  • Page 85 2. Engine Speed Control Dial The engine speed is controlled by the dial. Rotating it clockwise increases engine speed (rpm) counterclockwise decreases engine speed. Low idle (Lowest engine speed) High idle (Highest engine speed) NOTE: The auto idle system will automatically reduce engine speed to idle speed approximately four seconds after all of the control levers are in the HAOA690L...
  • Page 86 5. Engine Emergency Stop Switch If the engine does not stop when using the starter switch, it can be stopped by moving the engine emergency stop switch to "I" (EMERGENCY STOP) position. In this position, the engine emergency stop system is "OFF".
  • Page 87 Press the down button, to "DECREASE" volume. FG000021 Figure 12 Manual Scan: When pressing scan button once, for less than half-a-second, the frequency will be moved up in sequence to the next available signal. Auto Scan: When pressing scan button for more than a half-a-second, the frequencies are automatically scanned to the next higher one and will continue until button is again SCAN...
  • Page 88 8. Light Switch This switch is used to turn "ON" the lights. In this position, all lights are "OFF". In this position, all illumination lights of the instrument panel and the control switches are turned "ON". In this position, all illumination lights and work lights are turned "ON".
  • Page 89 10. Cabin Work Light Switch (Optional) This switch is used to control the cabin work lights, if unit is equipped with them. In this position, all cabin work lights are turned "OFF". In this position, the front cabin work lights on the front top of cabin will turn "ON".
  • Page 90 13. Wiper Switch Panel This panel is only for operation of the upper windshield wiper. When the wiper stops running, it moves to right side of the cabin, resting in its support. NOTE: When the front window is lifted, the wiper motor will not operate.
  • Page 91 14. Cigarette Lighter Push the lighter all the way into the socket and release your hand. After pushing it in, it will be ejected when it is heated. If it does not eject after a short time, pull it out and have it serviced.
  • Page 92 17. Seat Warmer Switch (Optional) If the seat is equipped with the optional seat warmer, push this switch to activate it. When the seat is warmed, the warmer is automatically turned "OFF". In this position, the seat warmer is turned "OFF". In this position, the seat warmer is turned "ON".
  • Page 93 20. Booster Button (Right-hand Work Lever) Press the lower button on the top of the right-hand work lever (joystick) to boost the hydraulic pressure. Refer to the "Boost Mode" on page 3-23. NOTE: This button works with the breaker/boost/shear selector switch. See "9. Breaker/Boost/Shear Selector Switch"...
  • Page 94 23. Safety Lever See "Safety Lever" on page 3-13. Unlock Lock EX1300566 Figure 33 24. Overload Warning Switch (Optional) If unit is equipped with an overload warning device, push this switch to activate it. In this position, the overload warning device is turned "OFF".

  • Page 95: Instrument Panel

    INSTRUMENT PANEL CHECK < CONNECTOR AND TERMINAL NO.> AMP 040 28P (CN7) (CN6) FG013521 Figure 36 Reference Reference Description Description Number Number Fuel Gauge Power Mode Selector Button (See page 2-31) Engine Coolant Temperature Gauge Economy Mode Selector Button (See page 2-31) Hydraulic Oil Temperature Gauge Auto Idle Selector Button Multifunction Gauge and Graphic...
  • Page 96 Functional check When the engine starter switch is turned to "I" (ON) position, all gauge bands, switch/button indicator lights and warning lights will turn "ON" and the alarm buzzer will sound about two seconds. During this functional check, a LOGO will appear on the multifunction gauge in the graphic information area (3 and 4, Figure 36).
  • Page 97 2. Engine Coolant Temperature Gauge The colored bands indicate the temperature of the engine coolant. WHITE ZONE ( ) - Indicates temperature is lower than the normal operating temperature. BLUE ZONE ( ) - Indicates temperature is within the normal operating range. RED ZONE ( ) - Indicates temperature is too high.
  • Page 98 4. Multifunction Gauge and Graphic Information Area See "Multifunction Gauge and Graphic Information" on page 2-25. This section will have a more in-depth explanation of the display area. FG013591 Figure 40 5. Digital Clock A digital clock, shows the current time. The displayed contents are as follows.
  • Page 99 8. Engine Oil Pressure Warning This symbol indicates when the engine starter switch is turned "ON", and should go "OFF" after the engine starts. For example, if the engine oil pressure becomes too low, the light will turn "ON" and a warning buzzer will sound. If this happens, shut the engine down immediately and determine the cause of the problem.
  • Page 100 10. Engine Check Warning This symbol indicates when the engine needs to be check. NOTE: If this symbol turns "ON" stop the machine and repair the cause of the fault. CHECK FG000045 Figure 46 11. Preheating Indicator In cold weather this symbol indicates that engine preheat function is operating.

  • Page 101: Multifunction Gauge And Graphic Information

    MULTIFUNCTION GAUGE AND GRAPHIC INFORMATION When the engine starter switch is turned to "I" (ON) position, a LOGO will appear on the display screen for about two seconds. When the LOGO disappears, the multifunction gauge and graphic information screen will appear. The engine rpm is normally displayed at the bottom of the screen when the starter switch is first turned "ON".
  • Page 102 Communication Error Warning If a communication error is generated between EPOS controller and instrument panel, this symbol will be displayed. When this symbol is displayed, contact a DOOSAN distributor or sales agency. NOTE: If a communication error occurs during operation, the last mode setting is stored.
  • Page 103 Front Hydraulic Pump Pressure The front pump pressure is numerically displayed. NOTE: This pump is closest to engine flywheel housing or is the upper one of hydraulic pump. FRONT PUMP It displays the reading in BARs. FG000051 Figure 55 Rear Hydraulic Pump Pressure The rear pump pressure is numerically displayed.
  • Page 104 Examples of Warning Display FG013705 FG013704 FG013703 <2 kinds of warning display> <4 kinds of warning display> <7 kinds of warning display> Figure 58 Hydraulic Oil Overheat Warning If the hydraulic oil temperature is too high, this symbol appears on the screen. FG000056 Figure 59 Fuel Shortage Warning...
  • Page 105 Return Filter Clogged Warning This symbol indicates when the hydraulic return filter is clogged. If this symbol is displayed, immediately stop operation and replace the return filter. After the return filter has been serviced, restart machine operation to remove warning symbol. FG000054 Figure 61 Air Cleaner Clogged Warning...
  • Page 106 Water In Fuel Warning This symbol indicates when the water is full in the fuel prefilter When this symbol appears drain the water from the fuel prefilter as soon as possible. FG013744 Figure 64 Operating Controls DX235LCR 2-30...

  • Page 107: Mode Selector Buttons

    MODE SELECTOR BUTTONS Power Mode Selector Button Economy Mode Selector Button Auto Idle Selector Button Flow Control Button FG013707 Figure 65 1. Power Mode Selector Button This power mode is suitable for heavy-duty work that requires a high operating speed. Push this button to turn power mode "ON"...
  • Page 108 3. Auto Idle Selector Button When the auto idle system is activated, the engine will automatically reduce speed to "IDLE" approximately four seconds after all of the control levers are in the neutral position. This system is designed to reduce fuel consumption and noise.

  • Page 109: Setting Main Menu

    SETTING MAIN MENU By using a combination of the selector buttons (Figure 71), you can review and set the contents of the display screen. Items such as language, time and filter/oil information can be checked, and if necessary, set with new information. FG013591 Figure 70 FG013712...
  • Page 110 2. Down Arrow Button Down arrow button ( ), is used to move a menu item "Down" or to "Right". FG013897 Figure 73 3. Display Selector Button (ESC - Escape) Display selector button ( ), is used to change the displayed information on the screen.
  • Page 111 Display Selection and Escaping Display Selection When the display button is pressed for more than three seconds, the main menu screen (Figure 79) is displayed. In the normal display screen, the engine speed (rpm), battery voltage (volt), front pump pressure (bar), and rear pump pressure (bar) can be displayed.
  • Page 112 Main Menu MAIN MENU The menu selection can be changed by pressing the "UP" ( 1. Language or "DOWN" ( ) buttons. The selected menu item will be 2. Set Clock highlighted, and a cursor will appear by the menu item. 3.
  • Page 113 Setting Method SET CLOCK Move the cursor to desired number by using the "SELECT" ) button. When selected the number will flash. 02:30:30 Set the time by using the "UP" ( ) or "DOWN"( 2003 11/04 buttons. • "+" ( ), "-"...
  • Page 114 Menu Display Order and Icon Explanation 1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Hyd. Oil Filter 5. Pilot Filter 6. Engine Oil 7. Hydraulic Oil 8. Coolant Water FG001358 Figure 86 Filter/Oils Operating Hour Reset Filter/Oil Information After changing a filter or oil, reset the operating hour to zero (Hrs: 0000).
  • Page 115 Adjust Display MAIN MENU When the cursor is on "Adjust Display", press the "SELECT" 1. Language ) button. The adjust display submenu will appear. 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password : UP : DOWN : SELECT FG013569...
  • Page 116 Set Password (Lock and Unlock) Use extreme care when setting the password for starting the engine. If a mistake is made when entering the number, and the number is excepted by the system, as being correct, that number will be the only one that will allow the security system to be activated or deactivated.
  • Page 117 Select adoption (lock) or nonadoption (unlock) at set : UP : DOWN : SELECT password menu. FG013718 NOTE: Keep in mind never to forget password. Figure 94 NOTE: Please contact a DOOSAN distributor, if you forget your password. Operating Controls DX235LCR 2-41...

  • Page 118: Flow Control

    FLOW CONTROL The flow control is used to set the proper flow rate for an optional attachment (If equipped). The flow control screen is accessed directly from the normal display screen without going through the main menu or any submenus. FG013591 Figure 95 When the flow control button (Figure 69 and Figure 96) is...
  • Page 119 Adjusting Flow Rate FLOW CONTROL Use "UP" ( ) or "DOWN" ( ) buttons to adjust flow rate. "UP" ( ) button is used to increase a flow rate. "DOWN" ( ) button is used to decrease a flow rate. Flow Control Step Pump Flow Setting (l/min) : APPLY...

  • Page 120: Operation Selection Display

    OPERATION SELECTION DISPLAY In the monitor you can see the application that is currently selected. Power Mode Selection FG013720 Figure 101 Standard Mode Selection FG013721 Figure 102 Economy Mode Selection FG013722 Figure 103 Operating Controls DX235LCR 2-44...
  • Page 121 Auto Idle Selection AUTO FG013723 Figure 104 Power Boost Selection FG013724 Figure 105 Breaker Selection FG013725 Figure 106 Shear Selection FG013726 Figure 107 Operating Controls DX235LCR 2-45...
  • Page 122 Quick Coupler Operation Selection (Optional) FG013728 Figure 108 Camera Mode Selector Button Camera mode selector button (optional) Push this button (1, Figure 109) to turn camera mode "ON" or "OFF". When the camera mode button is pushed to "ON" position, the camera window appears on the screen.

  • Page 123: Heater And Air Conditioner Control Panel

    HEATER AND AIR CONDITIONER CONTROL PANEL Location of Controls and Vents FG015907 Figure 110 The heater and air conditioner are combined into one unit under the operator's seat. The operator can control cabin temperature using the control panel installed in the switch panel. Operating Controls DX235LCR 2-47...
  • Page 124 Control Panel COOL WARM FG014376 Figure 111 Reference Reference Description Description Number Number Off Button Air Inlet Selector Button Air Conditioner Control Button Fan Speed Selector Button Air Outlet Selector Button Temperature Control Button NOTE: When the light switch is turned to "I" or "II" position, the LED for illuminating in the control panel will turn "ON".
  • Page 125 Air Conditioner Button This button activate or deactivate air conditioner. When the air conditioner is turned on, the LED is lightened. FG000105 Figure 113 Air Outlet Selector Button This button is used to select which combination of air outlets be used. MODE FG000096 Figure 114...
  • Page 126 Used to direct air flow to the front window and to operator's feet. FG015910 Figure 117 Air Inlet Selector Button This button is used to select fresh air from outside the cabin, or recirculate air within the cabin. Pressing this switch enables the choice between fresh air and recirculating air within the operator's cabin.
  • Page 127 Temperature Control Button COOL WARM FG014378 Figure 121 Memory Function The air conditioner panel has a memory function. When the starter switch is turned "OFF", the settings for the panel will be stored. When the excavator is started, the last stored setting will be used.

  • Page 128: Stereo

    STEREO Before operating the stereo or CD player, read operation manual enclosed with stereo. Stereo PUSH VOLUME SOUND TUNE ST RDS REG TA TP PTY AF DIR INT RPT RDM EQ FG017016 Figure 122 Reference Reference Description Description Number Number Power/Volume Control Preset Station AM Selection...

  • Page 129: Miscellaneous Electrical Devices

    MISCELLANEOUS ELECTRICAL DEVICES Cabin Light A light is installed on the top of the operator's cabin. The light will work despite starter switch position. NOTE: If light is left "ON" for a long time while the engine is not running, the battery will be discharged. FG014379 Figure 124 Pilot Cutoff Switch...
  • Page 130 When changing the fusible link, replace the fusible link with the same capacity part. Otherwise, a fire could break out in the wiring harness and/or other components of the circuit. Always use original DOOSAN parts. Fuse Boxes There are two fuse boxes (Figure 128) in the right cover behind the seat.

  • Page 131: Seat Adjustment

    SEAT ADJUSTMENT WARNING AVOID DEATH OR SERIOUS INJURY Adjust the seat position before starting operations or after changing the operator. Always fasten your seat belt while operating machine. Adjust the seat so that the control levers and pedals can be operated freely and easily with the operator back against the backrest.
  • Page 132 3. Suspension Adjustment Turning knob (3, Figure 129) to right makes the suspension harder. Turning knob to left makes the suspension softer. Adjust according to operator's weight by checking the weight indicator dial. Adjustment range is from 50 - 120 kg (110 - 265 lb). 4.
  • Page 133 8. Seat Belt WARNING AVOID DEATH OR SERIOUS INJURY The seat belt is for the operator's safety and should always be worn. Before driving the machine, adjust the seat to the desired position for maximum comfort and machine control, then fasten the seat belt. Seat belts must be worn across the pelvic region and adjusted snugly to lessen the chance and severity of injury in case of an accident.
  • Page 134 9. Seat Back-pocket The seat has a seat back pocket. It is used for storing the operation and maintenance manual. 10. Left and Right Control Stand Adjustment For operator's convenience, the right and left control stands and seat can slide together, within a 140 mm (6.3 in) forward or backward travel distance.

  • Page 135: Ceiling Cover

    CEILING COVER NOTE: If the machine is equipped with the transparent ceiling cover never use any chemical cleaners on its surface. Only use warm water to wash dust and dirt from its surfaces, and after that, dry it with a soft fabric towel.

  • Page 136: Front Windows

    FRONT WINDOWS WARNING AVOID DEATH OR SERIOUS INJURY When leaving operator's seat, move safety lever to "LOCK" position (Figure 138), if not a serious accident could occur Unlock by accidentally moving work levers. Lock EX1300566 Figure 138 Front Upper Window The front upper window can be housed in cabin's ceiling.
  • Page 137 Closing the Window WARNING AVOID DEATH OR SERIOUS INJURY Be careful that your hands are not caught in window frame. Lower bucket or work tool to ground. FG014392 Move safety lever (Figure 138) to "LOCK" position, and Figure 140 stop engine. Holding upper handles (1, Figure 140) of front window with left and right-hand, pull lock levers (2, Figure 140) to release the lock.

  • Page 138: Door Side Latch

    DOOR SIDE LATCH The door side latch (1, Figure 143) is used to secured door to side of cabin when it is opened. NOTE: Keep door closed and locked when machine is not in use. FG014395 Figure 143 To release door from side of cabin, push latch lever (1, Figure 144) down.

  • Page 139: Cabin Storage Compartments

    CABIN STORAGE COMPARTMENTS There are two storage compartments behind the operator's seat. The large compartment (1, Figure 145) is for storing nonperishable items. The covered other one (2, Figure 145) is interconnected with the air conditioner. So, it can be supplied with either warm or cool air when air conditioner is turned "ON".

  • Page 140: Sun Visor

    SUN VISOR The sun visor can be used to reduce the amount of sunlight coming through the front window and ceiling cover. When wanting to reduce the amount of sunlight coming through the front window, pull down bar (1, Figure 148) and hang on the hook (2, Figure 148).

  • Page 141: Emergency Glass Breaking Tool

    EMERGENCY GLASS BREAKING TOOL The excavator is equipped with a glass breaking tool. It is located to the left pillar of the cabin. This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the cabin. Grip handle firmly and use the sharp point to break glass.

  • Page 142: Miscellaneous Access Covers And Doors

    MISCELLANEOUS ACCESS COVERS AND DOORS Side Door Open side access door and slide prop rod (1, Figure 152) in slot (2) until it locks at end of slot. FG014403 Figure 152 Control Valve Door Opening Open door and place the tip of rod at the bracket hole of the door (1, Figure 153) latches.

  • Page 143: Operation

    Operation TO HANDLE A NEW EXCAVATOR All DOOSAN excavators are inspected and adjusted before leaving the factory. However, it is required that operator follow these steps during the initial break-in period. Failure to follow these steps can result in damage to the equipment or reduced performance.

  • Page 144: Starting And Stopping The Engine

    Lubrication and Filters Change engine oil and replace oil filter after first 50 hours of operation. Change swing reduction device oil after first 250 hours of operation. Change hydraulic oil return filter after first 250 hours of operation. Replace travel and reduction gear oil after first 250 hours of operation.
  • Page 145 Operational Checks Before Starting Engine WARNING Unlock AVOID DEATH OR SERIOUS INJURY When leaving operator's seat, set the safety lever to "LOCK" (Figure 1) position, if not a serious accident could Lock EX1300566 occur by accidentally moving the travel or work levers. Figure 1 Move safety lever to "LOCK"...
  • Page 146 Engine Start WARNING AVOID DEATH OR SERIOUS INJURY Start the engine after sounding horn and making sure there are no people or obstacles in the area. Perform all steps in "Operational Checks Before Starting Engine" on page 3-3. Set engine speed control dial slightly above "LOW IDLE" (Figure 3).
  • Page 147 After warming unit, check all operating indicators to make sure that all engine systems (oil pressure, coolant, etc.) are in the normal operating range. If any problems are noticed, CHECK stop engine. Normal indicators are: FG013731 Figure 6 Instrument Panel Light or Gauge Indicator Reading Engine Coolant Temperature Gauge Blue Range...
  • Page 148 Cold Weather Starting WARNING AVOID DEATH OR SERIOUS INJURY DO NOT USE STARTING FLUIDS. The preheat system could cause the starting fluid to explode. Starting fluids should never be used. Perform all steps in "Operational Checks Before Starting Engine". Set engine speed control dial slightly above "LOW IDLE" (Figure 7).
  • Page 149 After the preheat completion, immediately turn starter " " switch to (START) position (Figure 10). Engine should start in approximately five seconds. WARNING AVOID DEATH OR SERIOUS INJURY If the engine does not start after approximately fifteen FG000085 seconds of cranking, release the starter switch. Wait Figure 10 about five minutes and repeat above step.
  • Page 150 IMPORTANT The machine has a 24V (-) negative ground electrical system. Use the same capacity 24V booster batteries when jump starting engine. If the batteries are drained during starting procedures, jump-start engine using auxiliary or booster batteries according to the following procedure: Connecting the Booster Batteries Stop engine of the machine on which booster batteries (3,...
  • Page 151 Hydraulic System Warm-up WARNING AVOID DEATH OR SERIOUS INJURY If a problem or abnormal operation occurs, immediately stop engine. Allow excavator to reach normal operating temperature before starting work, especially in cold weather. The correct operating temperature of the hydraulic oil is 50° - 80°C (120°...
  • Page 152 Hydraulic System Warm-up – Cold Weather Run engine at "LOW IDLE" (no load) for five minutes (Figure 16). HAOB290L Figure 16 Run engine for approximately five minutes set at the middle of the speed range, without a load (Figure 17). HAOB410L Figure 17 Move safety lever to "UNLOCK"...
  • Page 153 Set engine speed control dial to "HIGH IDLE" (Figure 20). Repeat Step 4 for five minutes. If working speeds continue to be slow, continue to operate, but use extreme caution because the machine function may be erratic. Check for clearance and fully raise the front attachment. Slowly swing clockwise 3 revolutions.
  • Page 154 Stop engine by turning key to "O" (OFF) position (Figure 24). Remove key from starter switch. FG000175 Figure 24 Check and Confirmation After Stopping Engine Repair excavator, if there are any coolant or oil leaks. Inspect front attachment and under carriage for abnormal appearances.

  • Page 155: Safety Lever

    SAFETY LEVER WARNING AVOID DEATH OR SERIOUS INJURY When stopping engine or leaving the operator's seat, "LOCK" the safety lever, otherwise, a serious accident can occur by accidental movement of travel and work levers. Whenever leaving the operator's seat, make sure the engine is stopped and the safety lever is "LOCKED".

  • Page 156: Travel

    TRAVEL WARNING AVOID DEATH OR SERIOUS INJURY Before operating the travel levers, make sure that you know in which direction the machine is pointing. Look at the end of the track assemblies. If the drive motors are visible while sitting in the operator's seat, you are looking at the back end of the track assembly (therefore, you are looking backwards).
  • Page 157 Automatic Travel Speed Control WARNING AVOID DEATH OR SERIOUS INJURY Do not change the travel mode while traveling. Always use speed mode "O" when traveling down a slope. It is very dangerous to change to speed modes indicated "I" or "II" while going down a slope.
  • Page 158 Travel Control Lever Operation To travel straight (Figure 27), push both travel control levers/pedals fully forward or backwards. The farther the levers/pedals are pressed, the faster the travel speed. NOTE: "X" is the sprocket end of the track. "X" FG000303 Figure 27 Pivot turns (Figure 28) are made by rotating only one track forward or backward.
  • Page 159 General Travel Instructions Set engine speed control dial (Figure 31) on desired speed. HAOB550L Figure 31 Move safety lever to "UNLOCK" position, and folding the front, raise it 40 - 50 cm (16 - 20 in) above ground. See Figure 32. 40 ~ 50 cm FG015917 Figure 32...
  • Page 160 On rough, frozen or uneven terrain, travel slowly. WARNING AVOID DEATH OR SERIOUS INJURY When traveling, keep bucket from 20 - 30 cm (8 - 12 in) above ground. Do not travel backward on a slope. Never turn or travel crosswise on a slope. FG015880 Choose a safe alternate route before climbing a slope.
  • Page 161 Make sure that material buildup has been cleared. See Figure 37 and Figure 38. The excavator can travel in water that comes up to center of upper carriage rollers. Make sure that footing is solid so the machine will not sink. See "Working in Water" on page 3-31.
  • Page 162 Operating Forward Reverse NOTE: "X" is the sprocket end of the track. "X" FG018581 Figure 39 Locking Pedal When straight travel pedal in not needed, the pedal can be locked by using the prop rod (1, Figure 40) locking device. FG018582 Figure 40 Locking is completed when the top end of the prop (1) is...

  • Page 163: Operating Instructions

    OPERATING INSTRUCTIONS Engine Speed Control Engine speed can be manually adjusted using the engine speed control dial, Increase engine speed by rotating the control knob clockwise. Decrease engine speed by rotating the control knob counterclockwise. IMPORTANT The engine speed control system has been set at the HAOA690L factory and should not require adjustment as part of routine Figure 42...
  • Page 164 Economy Mode When the starter switch is turned "ON" the power mode is automatically defaulted to the standard setting. Select a proper power mode using button (2, Figure 44) before starting work. When the economy mode button (2, Figure 44) is pressed, a signal sounds, changing the economy mode to either "ON"...
  • Page 165 Boost Mode Power boost switch is used to gain maximum digging force. The power boost is activated while the lower button is being pressed on top of the right-hand work lever (joystick). The breaker/boost/shear selector switch must be in the "O" (BOOST) position. NOTE: The power boost mode does not affect forward and reverse travel.
  • Page 166 Work Levers (Joysticks) (ISO Pattern) WARNING AVOID DEATH OR SERIOUS INJURY Check surrounding area before swinging. When operating a lever while in auto idle, do it carefully, because the engine speed will increase rapidly. NOTE: When starting work, move work levers (joysticks) FG015921 slowly and check movement of swing and front Figure 47...
  • Page 167 Right-hand Work Lever (Joystick) (Figure 47 and Figure 50) Boom down Boom up Bucket crowd Bucket dump NOTE: Even after stopping the engine, the front can be lowered to the ground by operating work lever (joystick), by setting safety lever on "UNLOCK" position and turning starter switch "ON".
  • Page 168 Work Levers (Joysticks) (BHL Pattern) Left-hand Work Lever (Joystick) (Figure 51 and Figure 53) Boom down Boom up Left swing Right swing NOTE: The swing brake is spring applied and hydraulically released. It is always engaged when the work lever (joystick) is in "NEUTRAL"...

  • Page 169: Operating Precautions

    OPERATING PRECAUTIONS WARNING AVOID DEATH OR SERIOUS INJURY Do not rest your feet on the travel pedals during normal machine operation. Unexpected machine travel can occur in this situation. Before starting work, investigate terrain and soil condition. Level ground and drain area if necessary. Install window guards when working where there is a possibility of falling rocks or other objects.
  • Page 170 Do not use machine travel or swing when the bucket is in the ground to provide additional breakout force. See Figure FG015929 Figure 59 Do not use weight of machine to provide additional breakout force. See Figure 60. When working on soft or muddy ground, make sure that the machine is not sinking.
  • Page 171 11. Make sure there is adequate clearance from overhead electrical supply lines. See Figure 63. FG015879 Figure 63 12. If the excavation is in an underground location or in a building, make sure there is adequate overhead clearance and there is adequate ventilation. See Figure 64. FG015932 Figure 64 13.
  • Page 172 15. Do not operate travel lever quickly when traveling in high range. • Avoid sudden starts. • When traveling in one direction come to a complete stop before reversing directions. Do not rock excavator back and forth with levers. • Avoid sudden stops.
  • Page 173 Working in Water IMPORTANT When working in water, do not exceed a slope of more than 15°. If the slope is over 15°, the rear part of the upper structure will be immersed in water, resulting in radiator fan and engine ECU damage. FG015935 Figure 68 When working in water, do not operate in water over center of...

  • Page 174: Parking Excavator

    PARKING EXCAVATOR WARNING AVOID DEATH OR SERIOUS INJURY Park excavator on firm and level ground. Avoid parking on slopes. If excavator must be parked on a slope, block tracks and place bucket teeth in ground. See Figure 70. FG015937 Figure 70 Park excavator on firm and level ground.

  • Page 175: Towing Procedure

    TOWING PROCEDURE Cloth WARNING AVOID DEATH OR SERIOUS INJURY Never use a damaged wire rope or chain. They could brake Towing Wire and cause a serious accident. Always wear gloves when handling a chain or wire rope. When towing excavator use a wire rope or chain capable of handling the load.

  • Page 176: Hydraulic Attachments (Optional)

    If a hydraulic breaker is installed, consider equipment's stability and suitability for such modification. Also, consider hydraulic oil pressure and quantity. When selecting a hydraulic breaker consult with a DOOSAN distributor or sales agency. Hydraulic Hoses and Tubing for Breaker When installing hydraulic breaker, assemble according to drawings provided with kit.
  • Page 177 Breaker Operating Precautions NOTE: Hydraulic pressure and flow settings may need to be changed. Refer to the Maintenance Section of this manual for further information. Make sure to read and understand the breaker user's manual. Inspect all mechanical and hydraulic connections. Do not use the breaker as a hammer.
  • Page 178 Do not allow the breaker body to go into water if not equipped for underwater operation. The breaker seal can be damaged and allow rust, foreign material or water to enter the hydraulic system and cause damage. Only insert the breaker tool into water. See Figure 78. HAOB970L Figure 78 Do not any lifting or towing with a breaker.
  • Page 179 To activate breaker Set breaker selector switch to "II" (BREAKER) position. Press lower button on top of right-hand work lever (joystick) to activate hydraulic breaker. Release lower button on top of right-hand work lever (joystick) to deactivate hydraulic breaker. FG000117 Figure 82 Right-hand Work Lever (Joystick) Relief Valve Adjustment Cap pipe on arm end, using a cap capable of handling...
  • Page 180 100% 500 Hours 100 Hours Work These service intervals only apply, when a genuine DOOSAN oil and filter are used. If any other brands are used, the guaranteed changed interval must be reduced in half. 105 116 FILTER (First Replacement)

  • Page 181: Adjusting The Pump Flow

    ADJUSTING THE PUMP FLOW NOTE: For further information, see "Flow Control" on page 2-42. On the instrument panel, press the flow control button , the flow control screen (Figure 85) will be displayed. Use "UP" ( ) or "DOWN" ( ) buttons to adjust flow rate.
  • Page 182 Two-way Pedal Valve (Optional) Activating Shear with Pedal Valve Select shear with the selector switch of the right panel. Two-way operation is possible by rocking pedal back and forth between positions (1 and 2, Figure 86). When pedal is in its center (at rest) position, valve is in "NEUTRAL" and hydraulic oil flow is stopped.
  • Page 183 Rotating Pedal Valve (Optional) Attachment Rotating by Using the Pedal Valve Pressing end (1, Figure 89) is used to turn clockwise. Pressing Figure used turn counterclockwise. NOTE: Before activating the pedal, be sure to check the function of the attachment. FG000405 Figure 89 Locking the Pedal...

  • Page 184: Lifting Objects

    LIFTING OBJECTS IMPORTANT There may be local or government regulations, about the use of excavators for the lifting of heavy loads. Always contact your local and government agencies in regards to these regulations. When this machine is used in object handling applications, the machine must be properly configured and operated properly.
  • Page 185 Lifting Unknown Weight When loads are not accurately known are to be lifted, the person responsible for the job shall ascertain that the weight of the load FRONT LIFT does not exceed the machine LOAD RATING CHART at the ZONE radius at which it is to be lifted.

  • Page 186: Operation Under Unusual Conditions

    OPERATION UNDER UNUSUAL CONDITIONS NOTE: "Maintenance Special Conditions" page 4-83 for other recommendations. Operation In Extreme Cold In extremely cold weather, avoid sudden travel movements and stay away from even slight slopes. The machine could slide down the slope. Snow accumulation could hide potential hazards and slippery surfaces.
  • Page 187 Always keep the fuel tank fully filled after completion of the operation. Always drain water from the fuel tank before and after the operation. In addition, check the water separator, and drain it if required. The fuel filter, if frozen, may interrupt the flow of fuel.
  • Page 188 Formation of scale and rust in cooling system occurs more rapidly in extremely high temperatures. Change antifreeze each year to keep corrosion inhibitor at full strength. If necessary, flush cooling system periodically to keep passage clear. Avoid use of water with a high alkali content which increases scale and rust formation.
  • Page 189 Operation in Dusty or Sandy Areas Operation of the machine can cause dust in almost any area. However, when in predominantly dusty or sandy areas, additional precautions must be taken. Keep cooling system fins and cooling areas clean. Blow out with compressed air, if possible, as often as necessary. WARNING AVOID DEATH OR SERIOUS INJURY Wear goggles when using compressed air.
  • Page 190 Operation in Salt Water Areas The corrosive effect of salt water and salt water spray is very extensive. When operating in salt water areas, observe the following precautions. When exposed to salt water, dry machine thoroughly and rinse with fresh water as soon as possible. Keep all exposed surfaces coated with preservative lubricating oil.

  • Page 191: Inspection, Maintenance And Adjustment

    Inspection, Maintenance and Adjustment PREVENTIVE MAINTENANCE Routine maintenance and inspections are required to keep your machine in the correct operating condition. The following pages list the inspection intervals, the system or component checks, and location references. NOTE: The following pages list the service checks and their required intervals.
  • Page 192 Please make note of these numbers and their locations. These will be required whenever warranty or service work is requested. Keep this number on file, incase the machine is stolen. Figure 3 Doosan Infracore Co., Ltd. 7-11, Hwasu-dong, Dong-gu, Incheon, Korea MODEL PRODUCT IDENTIFICATION NUMBER...
  • Page 193 Component Serial Numbers There are many serial numbers on each traceable components of the machine. For example, the engine serial number is stamped on the rear left side of the engine block, above the starter. Additional engine information is described on a label (Figure 6) on the rocker cover.

  • Page 194: Preliminary Work Machine Setup For Maintenance

    PRELIMINARY WORK MACHINE SETUP FOR MAINTENANCE When performing maintenance specified in this manual, always park the excavator as follows. NOTE: Certain types of maintenance may require the machine to be positioned differently. Always return machine to this position. Park on firm and level ground. Lower bucket or work tool to ground.
  • Page 195 Stop engine by turning key to "O" (OFF) position. Remove key from starter switch. WARNING AVOID DEATH OR SERIOUS INJURY If engine must be run while performing maintenance, use extreme care. Always have one person in the cabin at all times. Never leave the cabin with the FG000175 engine running.

  • Page 196: Table Of Recommended Lubricants

    TABLE OF RECOMMENDED LUBRICANTS IMPORTANT It is highly recommend to use DOOSAN Genuine Products or products which meet the following specifications. Using other products can damage the equipment. NOTE: Refer to the "Description of Lubrication and Service Chart" on page 4-11 for locations.
  • Page 197 (Engine oil) - Engine oil must meet API CI-4/ACEA E5. Hydraulic oil change interval is 4,000 hours, only when DOOSAN Genuine Oil is used. If other brands of oil is used, guaranteed change interval is 2,000 hours. Note that mixing ratio is for reference purpose only, and is not an absolute standard.
  • Page 198 1 year or 2,000 hours. Therefore, it is recommended to use authorized genuine DOOSAN antifreeze solution. When using DOOSAN coolant, there is no need to use a corrosion resistor. For details, see "Engine Cooling System" on page 4-71.

  • Page 199: Fluid Capacities

    FLUID CAPACITIES Component Capacity 27 liters Oil Pan with Filter (7.1 U.S. gal.) Engine 30 liters Cooling System (8.0 U.S. gal.) 320 liters Fuel Tank (84.5 U.S. gal.) 130 liters Tank Level (34.3 U.S. gal.) Hydraulic Oil 230 liters System (60.8 U.S.

  • Page 200: Lubrication And Service Chart

    LUBRICATION AND SERVICE CHART Lubrication and service chart is on the inside of battery box cover. The symbols shown here are used in the lubrication and service chart on the next page. Symbol Description Symbol Description Lubrication Coolant Gear Oil (Swing Device, Travel Device) Air Cleaner Element Engine Oil Fuel Filter...
  • Page 201 Description of Lubrication and Service Chart 250h 500h 1000h 2000h EX1300918 Figure 12 Inspection, Maintenance and Adjustment DX235LCR 4-11...
  • Page 202 F100: Every 10 Hours For First 100 Hours. W10: Every 10 Hours If Operating In Water. EG: Ethylene Glycol - DOOSAN Genuine Antifreeze Solution (Drain and replace using this interval.) See "Engine Cooling System" on page 4-71, for further explanation.

  • Page 203: Maintenance Intervals

    MAINTENANCE INTERVALS SERVICE ITEM PAGE 10 Hour / Daily Service Grease Boom, Arm and Front Attachment Pins (for first 100 hours) 4-15 Check Engine Oil Level 4-15 Check Level of Hydraulic Oil Tank 4-16 Check for Leaks in Hydraulic System 4-17 Check Fuel Level 4-18...

  • Page 204: Service Item Page

    Major Parts - Periodic Replacement 4-62 12,000 Hour / Six Year Service Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) 4-63 ** These checks need to be completed by an authorized DOOSAN dealer. Inspection, Maintenance and Adjustment DX235LCR 4-14...

  • Page 205: 10 Hour / Daily Service

    10 HOUR / DAILY SERVICE Grease Boom, Arm and Front Attachment Pins (for first 100 hours) WARNING AVOID DEATH OR SERIOUS INJURY Do not remove grease fitting until pressure is entirely bled off by loosening grease fitting slowly to avoid fatal wound. FG000500 Let anybody never be in the blowing direction.

  • Page 206: Check Level Of Hydraulic Oil Tank

    Engine oil level must be between "HIGH" and "LOW" marks on dipstick. NOTE: If oil is above "HIGH" mark on dipstick, some must be drained to return oil to proper level. Add oil through engine oil fill cap (2, Figure 14), if the oil level is below the "LOW"...

  • Page 207: Check For Leaks In Hydraulic System

    Move safety lever to "LOCK" position. Check level gauge through right glass of cabin. Oil level must be between marks on sight gauge. FG015941 Figure 18 If the level is below "L" mark add oil. Stop engine. The hydraulic tank is pressurized. Lift the breather cap slowly to allow the pressurized air to vent.

  • Page 208: Check Fuel Level

    Check Fuel Level WARNING AVOID DEATH OR SERIOUS INJURY Use extreme safety precautions while refueling to prevent explosions or fire. Immediately clean up any split fuel. FG015944 At end of each work day, fill fuel tank. Add fuel through fuel Figure 21 fill tube (1, Figure 21).

  • Page 209: Check Water Separator & Pre Fuel Filter (Fuel Prefilter) And Drain Water As Required

    Check Water Separator & Pre Fuel Filter (Fuel Prefilter) and Drain Water as Required NOTE: If water in fuel warning light (Figure 23) on instrument panel comes "ON", drain the collected water in fuel prefilter. FG013894 Figure 23 A fuel prefilter is inside the right rear side access door. Open the access door on right rear side of the machine.

  • Page 210: Check Oil Level Of Swing Reduction Device

    Check Oil Level of Swing Reduction Device WARNING AVOID DEATH OR SERIOUS INJURY The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. Before fully removing any motor case inspection port plug, etc., loosen the plug slightly to allow pressurized air to escape.

  • Page 211: Clean Dust Net In Front Of Oil Cooler And Intercooler

    Clean Dust Net in Front of Oil Cooler and Intercooler IMPORTANT If running excavator in dusty area, check dust net everyday and clean it if dirty. FG015947 Figure 29 WARNING AVOID DEATH OR SERIOUS INJURY If using compressed air or water to clean the dust net, make sure that proper eye protection is worn.

  • Page 212: Check Level Of Window Washer Liquid

    Do not allow the replaceable bucket teeth to wear down to the point that the bucket adapter is exposed. See Figure NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers' buckets, refer to their specific instructions.

  • Page 213: Inspect Cooling Fan Blade

    Check the engine intake hose, and hose bands for damage and tightness. If damaged, wrinkled, or loose, replace or retighten or contact your nearest DOOSAN dealer. IMPORTANT Severe engine damage will result from running with unfiltered air. FG005853...

  • Page 214: Inspect Structure For Cracks And Faulty Welds

    "LOCK" position. Contact your DOOSAN distributor immediately if the controls do not deactivate. DO NOT MODIFY THE SYSTEM. Inspection and Maintenance of the Pilot Cutoff Switch Check for and keep bystanders away from the work area.

  • Page 215: Check Operation Of All Exterior Lights, Horn And Control Console Indicator And Monitor Lights

    DOOSAN distributor immediately for service. DO NOT MODIFY THE SYSTEM. Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights Turn engine starter switch to "I"...

  • Page 216: Check Operation Of All Controls

    Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal Operating Temperature. Listen for Any Abnormal Sounds Check Operation of All Controls IMPORTANT Cold weather operation requires that the operator fully warm up the hydraulic oil before beginning machine operation.

  • Page 217: 50 Hour / Weekly Service

    50 HOUR / WEEKLY SERVICE Perform All Daily Service Checks Grease Arm and Front Attachment Pins Grease every 10 hours for first 100 hours and every 50 hours thereafter. NOTE: If the unit has been running or working in water the front attachment must be greased on a 10 hour/daily basis.

  • Page 218: Grease Swing Bearing

    Arm link joint pin (1 point) Link joint pin (2 points) Arm bucket joint pin (1 point) Bucket link joint pin (1 point) FG009561 Figure 39 Bucket cylinder rod pin (1 point) FG000142-1 Figure 40 Grease Swing Bearing Park machine on firm and level ground. Lower the front attachment to the ground and stop engine.

  • Page 219: Drain Water And Sediment From Fuel Tank

    Drain Water and Sediment from Fuel Tank Perform this procedure before operating the machine. Drain Water and sediment from bottom of pump room into a suitable container. NOTE: Dispose of drained fluid according to local regulations. NOTE: Always completely fill fuel tank at end of each workday to prevent condensation from forming on the inside walls of the tank.

  • Page 220: 250 Hour / Monthly Service

    250 HOUR / MONTHLY SERVICE Perform All Daily and 50 Hour Service Checks Grease Arm and Front Attachment Pins Grease every 10 hours for first 100 hours and every 250 hours thereafter. NOTE: If the unit has been running or working in water the front attachment must be greased on a 10 hour/daily basis.
  • Page 221 Boom cylinder head pin (2 points) FG001389 Figure 45 Boom foot pin (2 points) Boom cylinder rod pin (2 points) Arm cylinder head pin (1 point) FG015980 Figure 46 Boom arm joint pin (2 points) Arm cylinder rod pin (1 point) Bucket cylinder head pin (1 point) FG001391 Figure 47...

  • Page 222: Check Engine Fan Belt Tension

    Check Engine Fan Belt Tension 10 mm/10 kg Alternator IMPORTANT A loose fan belt can cause engine overheating, poor charging, and/or premature belt wear. A belt that is too tight Compressor can cause damage to the water pump, alternator bearing or belt.

  • Page 223: Check Engine Fan Belt Wear

    Check Engine Fan Belt Wear WARNING AVOID DEATH OR SERIOUS INJURY Keep clear of engine fan and fan drive belts when the engine is running. Rotating fan and belt contact can cause injury. Figure 49 WARNING AVOID DEATH OR SERIOUS INJURY When checking, adjusting or replacing drive belts, care must be taken to prevent accidental cranking of the engine.

  • Page 224: Change Breaker Filter (Optional)

    Change Breaker Filter (Optional) WARNING The hydraulic oil will be hot after normal machine operation. Allow the system to cool down before changing pilot filter. Park machine on firm and level ground. Lower the front attachment to the ground and stop engine. Loosen the hydraulic oil tank breather cap to release FG015982 pressure.

  • Page 225: Replace Hydraulic Oil Return Filter (After First 250 Hours)

    Replace Hydraulic Oil Return Filter (After First 250 Hours) NOTE: Replace hydraulic oil return filter after first 250 hours of operation or rebuild, then every 1,000 hours thereafter (See page 4-47). Change Pilot Filter (After First 250 Hours) NOTE: Change pilot filter after first 250 hours and every 1,000 hours thereafter (See page 4-48).

  • Page 226: 500 Hour / 3 Month Service

    500 HOUR / 3 MONTH SERVICE Perform All Daily, 50 and 250 Hour Service Checks Grease Swing Gear and Pinion WARNING AVOID DEATH OR SERIOUS INJURY Greasing swing gear and pinion must be serviced by only one person. Remove inspection cover and inspect the condition of the grease.
  • Page 227 Change Engine Oil and Filter NOTE: Change engine oil and filter after first 50 hours of operation or rebuild, then every 500 thereafter. WARNING AVOID DEATH OR SERIOUS INJURY DO NOT change oil on a hot engine. Allow the engine to cool down before attempting to change the engine oil and filter to avoid burns by touching hot engine parts.
  • Page 228 Clean Air-Conditioning Outer Filter The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator's cabin. This filter must be cleaned out. NOTE: In the unit is being operated in a dusty environment, the cleaning and replacement must be performed more frequently.
  • Page 229 Remove filter (3, Figure 58) and inspect for any damage. Use compressed air to clean filter. If filter is still dirty, then change to new one. Reassemble filter and cover in reverse order. FG016062 Figure 58 Check and Clean Air-Conditioning Inner Filter WARNING AVOID DEATH OR SERIOUS INJURY...
  • Page 230 Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core WARNING AVOID DEATH OR SERIOUS INJURY If compressed air, steam or water hit your body directly, there is danger of injury. Always wear protective glasses, mask and safety shoes during the cleaning precess. Make sure that all extra personnel are clear of the work area.
  • Page 231 Clean Outer Filter of Air Cleaner NOTE: Clean outer filter every 500 hours/3 months of service. NOTE: If air cleaner clogged warning light (Figure 63) on instrument panel comes "ON" the air cleaner must be serviced. NOTE: When working in severely dusty conditions, the service interval must be shortened.
  • Page 232 Clean the outer filter (4, Figure 65) by blowing compressed air from the inside of the filter towards the outside. Do not use more than 205 kPa (30 psi) air pressure. HAOC570L Figure 66 Check outer filter by shinning a light through it. If small holes or thinner parts are found on the element after cleaning it, replace the filter.
  • Page 233 Change of Water Separator & Pre Fuel Filter (Fuel Prefilter) Open the right rear side door to access fuel prefilter. Position a small container under prefilter. Drain fuel by opening drain valve on bottom of filter. NOTE: Dispose of drained fluids in compliance with all applicable environmental laws and regulations.
  • Page 234 Change Main Fuel Filter WARNING AVOID DEATH OR SERIOUS INJURY Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. Access fuel filter through right side door. FG005879 Figure 71 Position a small container under fuel filter. Unscrew fuel filter from head assembly.
  • Page 235 Check Oil Level in Travel Reduction Device (One on Each Side of Unit) WARNING AVOID DEATH OR SERIOUS INJURY The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. FG028838 Before removing the motor case, loosen the plug slightly to Figure 74...

  • Page 236: 1,000 Hour / 6 Month Service

    1,000 HOUR / 6 MONTH SERVICE Perform All Daily, 50, 250 and 500 Hour Service Checks Grease Swing Reduction Device Park machine on firm and level ground. Lower the front attachment to the ground and stop engine. Remove air vent plug (1, Figure 75) from swing reduction device.
  • Page 237 Replace Hydraulic Oil Return Filter NOTE: Change hydraulic oil return filter after first 250 hours of operation or rebuild, and every 1,000 hours thereafter. NOTE: If return filter clogged warning light (Figure 78) on instrument panel comes "ON" the return filter must be serviced.
  • Page 238 Change Pilot Filter NOTE: Change pilot filter after first 250 hours of operation or rebuild, and every 1,000 hours thereafter. FG013895 Figure 81 WARNING AVOID DEATH OR SERIOUS INJURY The hydraulic oil will be hot after normal machine operation. Allow the system to cool down before changing pilot filter. Park machine on firm and level ground.
  • Page 239 Change Oil in Travel Reduction Device (One on Each Side of Unit) WARNING AVOID DEATH OR SERIOUS INJURY The gear oil is very hot after the machine has been operating. Shut all systems down and allow them to cool. FG028838 Before removing the motor case, loosen the plug slightly to Figure 83 allow pressurized air to escape.
  • Page 240 Change Swing Reduction Device Oil NOTE: Change swing reduction device oil after first 500 hours of operation or rebuild and every 1,000 hours thereafter. WARNING AVOID DEATH OR SERIOUS INJURY FG015945 The gear oil is very hot after the machine has been Figure 84 operating.
  • Page 241 Change Air-Conditioning Outer Filter The unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator's cabin. This filter must be cleaned out. NOTE: In the unit is being operated in a dusty environment, the cleaning and replacement must be performed more frequently.
  • Page 242 Change Air-Conditioning Inner Filter WARNING AVOID DEATH OR SERIOUS INJURY All service and inspection of air-conditioning system must be performed with the starter switch in the "O" (OFF) position. Open the cover by removing knobs (1, Figure 59). FG015051 Remove screw (2, Figure 60) and filter (3, Figure 60) from Figure 90 the cover.
  • Page 243 Check Air Conditioner Refrigerant WARNING AVOID DEATH OR SERIOUS INJURY Mixing of tobacco smoke and freon is deadly. smoke while servicing recharging air-conditioning system. FG016038 Contact with refrigerant can result personal injury, frost bite. Figure 92 Wear Protective glasses when refrigerant lines are opened. System may still under pressure, release it slowly in a well ventilated area.
  • Page 244 Change Fuel Cap Filter WARNING AVOID DEATH OR SERIOUS INJURY External shock or damages to fuel cap may lead to permanent damage to filter. FG015720 Figure 93 See under the fuel cap as shown on (Figure 94). Rotate bolt to CCW direction to loosen. FG015684 Figure 94 After disengaging it as shown on (Figure 95), carefully lay it...
  • Page 245 After exchanging to a new filter, you may now assemble back in reverse order. FG015688 Figure 98 Check and Adjust Engine ** Contact your nearest DOOSAN dealer. Engine dealer for checking and adjusting the following items: • Engine Compression Pressure. •...

  • Page 246: 2,000 Hour / Yearly Service

    2,000 HOUR / YEARLY SERVICE Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks Replace Outer and Inner Air Cleaner Elements WARNING AVOID DEATH OR SERIOUS INJURY Never clean or attempt to remove the air cleaner element if the engine is running.
  • Page 247 Therefore, it Is recommended authorized DOOSAN genuine antifreeze solution. To achieve the best cooling performance, keep the mixing ratio of the antifreeze and water by 50 : 50. Using water only can corrode the coolant circuit.
  • Page 248 Slowly open the radiator cap to allow any pressure to escape. Place a container under the radiator and open the drain valve (2, Figure 104). NOTE: Dispose of drained fluids in compliance with all applicable environmental laws and regulations. FG001407 Figure 104 Remove coolant drain plug (1, Figure 105) from engine.
  • Page 249 Hydraulic oil change interval is 2,000 hours, only when DOOSAN Genuine Oil is used. If another brand of oil is used, guaranteed change interval is 1,000 hours. NOTE: Based on the type of excavating being completed,...
  • Page 250 Drain hydraulic oil from tank into a container capable of holding 147.8 liters (39 U.S. gal.). After draining tank, install drain plug. IMPORTANT Be careful of squirting oil when removing drain plug. NOTE: Used filter and used oil should always be disposed of according to local regulations.
  • Page 251 Check Alternator and Starter** **These checks need to be completed by an authorized DOOSAN dealer. Check All Rubber Antivibration Shock Mounts Perform and Record Results of Cycle Time Tests Inspect Machine to Check for Cracked or Broken Welds or other Structural...

  • Page 252: Hour / Biennial Service

    4,000 HOUR / BIENNIAL SERVICE Major Parts - Periodic Replacement To ensure safe operation and work, perform periodic inspections. Also, to increase safety, replace the following parts. These parts are the ones most often subjected to abrasion, heat and fatigue. Exchange these parts with new ones at the designated time intervals, even if the old parts look good.

  • Page 253: 12,000 Hour / 6 Year Service

    Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) European regulations state that in-service life of any hydraulic hose may not exceed six years. DOOSAN recommends the following: • Hoses at the customer premises cannot be stored more than 2 years before being discarded or installed on a machine.

  • Page 254: Air-Conditioning System

    Check the hose for cracking and damage. CAUTION AVOID INJURY When a leak occurs, dirt will accumulate in the area where the leak is. Consult a DOOSAN distributor or sales agency. Check Condenser Inspect the condenser for dust and debris. Clean if necessary. NOTE: See "Clean Radiator, Oil Cooler, Intercooler, Fuel...

  • Page 255: Bucket

    Shut the engine off and lock out the hydraulic controls before working on the bucket. NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers buckets, refer to their specific instructions. HAOC680L...
  • Page 256 Bucket O-ring Replacement WARNING AVOID DEATH OR SERIOUS INJURY Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins. FG006750 Figure 114 Inspect bucket O-rings on a routine basis. If worn or damaged, replacement is necessary.

  • Page 257: Electrical System

    ELECTRICAL SYSTEM NOTE: Never disassemble electrical or electronic parts. Consult with a DOOSAN distributor or sales agency before servicing. Battery WARNING AVOID DEATH OR SERIOUS INJURY Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water.
  • Page 258 Inspection of Battery Electrolyte Level This machine has two maintenance free batteries. They never require the addition to water. When the charge indicator becomes transparency, it means low electrolyte state because of the leakage or charging system error. Determine the cause of problem and replace the batteries immediately.
  • Page 259 Fuses The fuses in the fuse box are used to protect the various electrical circuits and their components from being damaged. See Figure 120. The fuses used are standard automotive type fuses. The section on "Fuse Identification" on page 4-70, lists the circuits and the fuse amperage required for each circuit.
  • Page 260 Fuse Identification Fuse Box (1) Fuse Box (2) FG004974 Figure 122 Fuse Box One Fuse Box Two Name Capacity Name Capacity Warning Light (Optional) Horn 2-pump (Optional) Quick Coupler (Optional) Cigar Lighter Travel Alarm (Optional) 12V Power Auxiliary Mode Wiper, Washer Check Connector Lower Wiper (Optional) Pilot Cutoff...

  • Page 261: Engine Cooling System

    ENGINE COOLING SYSTEM General Keeping an engine's cooling system in peak operating condition can have many benefits in keeping a machine in good operating condition. A properly functioning cooling system will improve fuel efficiency, reduce engine wear, and extend component life. Always use distilled water in the radiator.
  • Page 262 Types of Antifreeze Ethylene Glycol - DOOSAN Genuine Antifreeze Solution  (for all seasons) Ethylene glycol is a very hazardous material to human beings, animals and environment. Drain of coolant must be disposed of by an authorized waste material treatment service provider.
  • Page 263 Antifreeze Concentration Tables Ethylene Glycol - DOOSAN Genuine Antifreeze Solution (for all seasons) (2,000 Hour/1 Year) Ambient Temperature Cooling Water Antifreeze -20°C (-4°F) -25°C (-13°F) -30°C (-22°F) -40°C (-40°F) NOTE: The concentration shall be kept at 50% and in worst case at 30% minimum for the least corrosion resistance.

  • Page 264: Fuel Transfer Pump (Optional)

    FUEL TRANSFER PUMP (OPTIONAL) IMPORTANT Dry operating fuel pump for more than fifteen seconds can cause wear and/or damage to pump. • Cooling and lubrication of pump is achieved by fuel passing through pump. If pump is dry operated, heat generated by moving parts will cause damage to pump rotors, vanes and seals.
  • Page 265 WARNING AVOID DEATH OR SERIOUS INJURY If there are any sign of leakage while operating transfer pump, inspect the following components to prevent any fires or hazardous fuel spills. • Check all hoses leading to and from the transfer pump. •...
  • Page 266 Remove strainer cap (4, Figure 123) from strainer (3) on end of inlet hose (5). NOTE: Keep strainer cap (4, Figure 123) in a safe location to reseal strainer (3) after refueling is complete. Insert inlet hose (5, Figure 123) into refueling tank. Turn on the switch of fuel pump in the pump room....

  • Page 267: Handling Of Accumulator

    • DO NOT weld on accumulator, or try attaching anything to it. • When replacing an accumulator, contact a DOOSAN distributor or sales agency so the gas can be properly released. • Wear safety goggles and protective gloves when working on an accumulator.

  • Page 268: Track Tension

    TRACK TENSION WARNING AVOID DEATH OR SERIOUS INJURY Measuring track tension requires two people. One person must be in the operator's seat, operating the controls while the other person makes dimensional checks. Block frame to make sure the machine won't move or shift position during service.
  • Page 269 A track that is properly adjusted may have a different sag according to the track options. Contact your dealer for information. Terrain Type Distance "A" 330 ~ 360 mm Normal (13.0 ~ 14.2 in) WARNING AVOID DEATH OR SERIOUS INJURY The track adjusting mechanism is under very high-pressure.

  • Page 270: Venting And Priming Hydraulic System

    VENTING AND PRIMING HYDRAULIC SYSTEM Main System Pump NOTE: If pump is run without sufficient oil in the main hydraulic pump, damage can occur. Always vent pump of air after draining hydraulic system. With the engine stopped, remove vent plug (Figure 129) to see if any oil is present.
  • Page 271 Swing Motor IMPORTANT If the air is not vented from the system, it will cause damage to the swing motor and bearings. NOTE: Perform this only when oil has been drained from swing motor. FG016002 Figure 130 Stop engine. Disconnect drain hose and fill swing motor case with hydraulic oil.

  • Page 272: Long Term Storage

    LONG TERM STORAGE Perform the following if storing the excavator for more than one month. Conditions Maintenance Required Cleaning Pressure wash the undercarriage and track assemblies. Inspect for damage or loose or missing parts. Lubrication Perform all daily lubrication procedures. Apply a coating of light oil to the exposed plated metal surfaces, such as hydraulic cylinder rods, etc.

  • Page 273: Maintenance In Special Conditions

    MAINTENANCE IN SPECIAL CONDITIONS NOTE: See "Operation Under Unusual Conditions" on page 3-44 for other recommendations. Conditions Maintenance Required Operating in mud, water or rain. Perform a walk around inspection to check for any loose fittings, obvious damage to the machine or any fluid leakage. After completing operations, clean mud, rocks or debris from the machine.
  • Page 274 Inspection, Maintenance and Adjustment DX235LCR 4-84...

  • Page 275: Transportation

    Attachment Removal DANGER AVOID DEATH DOOSAN warns any user, that removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
  • Page 276 WARNING AVOID DEATH OR SERIOUS INJURY When transporting the machine, know the width, height, length and weight. Loading or unloading the machine can be a dangerous operation. Make sure to run the engine at the lowest speed setting, and travel at the slowest speed possible. Make sure that ramp being used can handle the weight of the machine.
  • Page 277 Set the travel speed selector switch to "O" (OFF) position. See Figure 3. FG000023 Figure 3 Turn "OFF" auto idle selector button (1, Figure 4). The indicator symbol will be disappeared. Move engine speed to "LOW IDLE". FG013833 Figure 4 If the machine is equipped with work equipment, set the work equipment at the front, and travel forward to load it.
  • Page 278 Extend bucket and arm cylinders to maximum length and then lower the boom slowly. FG016005 Figure 7 10. Move safety lever to "LOCK" position. Unlock Lock EX1300566 Figure 8 11. Stop engine by turning key to "O" (OFF) position (Figure 12.
  • Page 279 FG016071 Figure 11 Transportation DX235LCR...

  • Page 280: Lifting Machine

    LIFTING MACHINE WARNING AVOID DEATH OR SERIOUS INJURY Never lift the machine with a person in the cabin or on the machine. Never enter the area under or around a raised machine. Improper lifting can allow load to shift and cause death or serious injury or property damage.

  • Page 281: Specification

    Specification STANDARD SPECIFICATION Specification Component Metric English CECE 0.81 m 1.06 yd Bucket Capacity PCSA 0.92 m 1.20 yd Operating Weight 24.3 metric tons 26.8 tons Model DL06 Type Water Cooled - 6 Cylinders Engine Rated Net Output 169 ps @ 1,900 rpm 166 hp @ 1,900 rpm Maximum Torque 78 kg•m @ 1,400 rpm...

  • Page 282: Overall Dimensions

    OVERALL DIMENSIONS FG016007 Figure 1 Boom Type (One Piece) 5.7 m (18' 8") Arm Type 2.9 m (9' 6") 2.4 m (7' 10") Bucket Type (SAE) 0.92 m 1.05 m Shipping Length 8,955 mm (29' 4") 9,010 mm (29' 7") Tail Swing Radius 1,680 mm (5' 6") Tumbler Distance...
  • Page 283 Specification DX235LCR...

  • Page 284: Working Range

    WORKING RANGE Ground FG016008 Figure 2 Specification DX235LCR...
  • Page 285 Boom Type (One Piece) 5.7 m (18' 8") Arm Type 2.9 m (9' 6") 2.4 m (7' 10") Bucket Type (PCSA) 0.92 m 1.05 m Max. Digging Reach 9,820 mm (32' 3") 9,415 mm (30' 11") Max. Digging Reach (Ground) 9,630 mm (31' 7") 9,215 mm (30' 3") Max.

  • Page 286: Approximate Weight Of Workload Materials

    APPROXIMATE WEIGHT OF WORKLOAD MATERIALS IMPORTANT Weights are approximations of estimated average volume and mass. Exposure to rain, snow or groundwater; settling or compaction because of overhead weight and chemical or industrial processing or changes because of thermal or chemical transformations could all increase value of weights listed in table.
  • Page 287 Density Density Density Density 1,200 kg/m 1,500 kg/m 1,800 kg/m 2,100 kg/m Material (2,000 lb/yd (2,500 lb/yd (3,000 lb/yd (3,500 lb/yd or less or less or less or less 1,522 kg/m Gypsum, crushed to 3 inch size (2,565 lb/yd 1,810 kg/m Gravel, DRY, packed fragments (3,051 lb/yd 1,922 kg/m...
  • Page 288 Specification DX235LCR...

  • Page 289: Index

    1INDEX Numerics 4-46 2-53 1,000 Hour / 6 Month Service Cabin Light 4-15 2-63 10 Hour / Daily Service Cabin Storage Compartments 4-63 2-13 12,000 Hour / 6 Year Service Cabin Work Light Switch 4-56 2-59 2,000 Hour / Yearly Service Ceiling Cover 4-30 4-46...
  • Page 290 4-69 Fuses 2-54 Fusible Link EC Declaration of Conformity 4-70 Identification 2-31 Economic Mode Selector Button 2-44 Economy Mode Selection 1-17 Electric Welding Attention 4-67 Electrical System Gauges 1-12 Emergency Exit 2-21 Engine Coolant Temperature Gauge Engine 2-20 Fuel Gauge 4-61 Adjust Valve Clearance 2-22...
  • Page 291 2-22, 2-25 Warm-up Multifunction Gauge 1-13 4-35 Impact Hazard (Optional) Nuts and Bolts Indicator 2-25 Communication Indicator Indicator Lights 4-21 Oil Cooler Dust Net 2-22 Charge Warning 4-45 Oil Level of Travel Reducer 2-23 Coolant Temperature Warning 2-60 Opening the Window 2-24 Engine Check Warning 3-20...
  • Page 292 2-24 Preheating Light Check and Confirmation After Stopping Engine 3-12 Preliminary Work Machine Setup for Maintenance 3-11 Engine Shutdown 1-11 3-32 Pressurized Gas and Fluid Parking Excavator 2-66 Preventive Maintenance Side Door Pump Pressure Specification 2-27 2-44 Front Pump Standard Mode Selection 2-27 Rear Pump Standard Specification...
  • Page 293 2-16 Rotating Buttons Unloading and Loading 2-16 2-33 Seat Warmer (Optional) Up Arrow Button 2-34 Selection Button 2-17 Shear Buttons Starter Switch 4-80 Venting and Priming Hydraulic System 2-11 Travel Speed Selector Switch 4-81 General Venting 2-15 Travel/Swing Alarm (Optional) 4-80 Hydraulic Cylinders 2-33...
  • Page 294 Index DX235LCR...
  • Page 296 If in an enclosed area, vent the exhaust to the outside. • Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary. For more information go to www.P65 warnings.ca.gov/diesel. Doosan Infracore North America 2905 Shawnee Industrial Way Suite 100 Suwanee, GA 30024...

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