Doosan Dx235lcr

EXCAVATOR
Operation &
Maintenance
Manual
DX235LCR
Serial Number 5001 and Up
950106-00082DE
September 2018
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
©Operation
Doosan Infracore 2018
and Maintenance Manual Copyright Doosan 2011
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............................................................. 1-21
Before Starting Engine..................................................................... 1-30
Machine Operation........................................................................... 1-35
Maintenance .................................................................................... 1-43
Battery.............................................................................................. 1-52
Towing ............................................................................................. 1-54
Shipping and Transportation............................................................ 1-55
Excavator Rated Lift Capacity Tables.............................................. 1-56
Operating Controls ....................................................................2-1

Component Locations ........................................................................ 2-2
Operator's Area.................................................................................. 2-4
Operational Controls and Panels ....................................................... 2-6
Instrument Panel.............................................................................. 2-19
Multifunction Gauge and Graphic Information ................................. 2-25
Mode Selector Buttons..................................................................... 2-31
Setting Main Menu ........................................................................... 2-33
Flow Control..................................................................................... 2-42
Operation Selection Display............................................................. 2-44
Heater and Air Conditioner Control Panel........................................ 2-47
Stereo .............................................................................................. 2-52
DX235LCR Table of Contents

I
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........................................ 2-66
Operation....................................................................................3-1
To Handle a New Excavator .............................................................. 3-1
Starting and Stopping the Engine ...................................................... 3-2
Safety Lever..................................................................................... 3-13
Travel ............................................................................................... 3-14
Operating Instructions...................................................................... 3-21
Operating Precautions ..................................................................... 3-27
Parking Excavator............................................................................ 3-32
Towing Procedure............................................................................ 3-33
Hydraulic Attachments (Optional) .................................................... 3-34
Adjusting the Pump Flow ................................................................. 3-39
Lifting Objects .................................................................................. 3-42
Operation Under Unusual Conditions .............................................. 3-44
Inspection, Maintenance and Adjustment...............................4-1

Preventive Maintenance .................................................................... 4-1
Preliminary Work Machine Setup for Maintenance............................ 4-4
Table of Recommended Lubricants ................................................... 4-6
Fluid Capacities ................................................................................. 4-9
Lubrication and Service Chart.......................................................... 4-10
Table of Contents DX235LCR

II
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 .......................................................... 4-62
12,000 Hour / 6 Year Service........................................................... 4-63
Air-Conditioning System .................................................................. 4-64
Bucket .............................................................................................. 4-65
Electrical System ............................................................................. 4-67
Engine Cooling System.................................................................... 4-71
Fuel Transfer Pump (Optional) ........................................................ 4-74
Handling of Accumulator.................................................................. 4-77
Track Tension .................................................................................. 4-78
Venting and Priming Hydraulic System............................................ 4-80
Long Term Storage .......................................................................... 4-82
Maintenance in Special Conditions.................................................. 4-83
Transportation ...........................................................................5-1
Loading and Unloading ...................................................................... 5-1
Lifting Machine................................................................................... 5-6
Specification ..............................................................................6-1
Standard Specification ....................................................................... 6-1
Overall Dimensions............................................................................ 6-2
Working Range .................................................................................. 6-4
Approximate Weight of Workload Materials....................................... 6-6
Index ...........................................................................................7-1
DX235LCR Table of Contents

III
Table of Contents DX235LCR
IV
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
Technical file : Doosan Benelux SA, Drève Richelle 167, 1410 Waterloo, (Belgium)
Brand : Doosan
Model Name : DX235LCR
Serial Number :
Year of Manufacturing. :
Engine Manufacturer : Doosan
Engine Model : DL06
Net Installed Power : 128.7 kW / 1,900 rpm (SAE J1995)
Net Power : 123.5 kW / 1,900 rpm (SAE J1349)
Pertinent EC noise emission requirement :
Has been manufactured in conformity with the provisions of the Directive 2000/14/EC, 
as stated below;
Certificate No. : SNCH*2000/14*2005/88*2508*00
Certification Issued Date : November 12th, 2014
Conformity Assessment Procedure : Annex VIII Full Quality Assurance
Notified Body Involved : Société Nationale de Certification et d'Homologation (SNCH) 
2a. Kalchesbruck, L-1852 Luxemburg (Luxembourg)
Notified Body 0499 for EC Directive 2000/14/EC
Measured Sound Power Level : 102 dB(A)
Guaranteed Sound Power Level : 103 dB(A)
Has been manufactured in conformity with the provisions of 
2006/42/EC (Machinery), 97/68/EC (Exhaust Gas Emission),
2004/108/EC or 2014/30/EU (Electromagnetic Compatibility)
Designed and manufactured in accordance with the sound engineering practice as valid for Class I
or Article 3.3 items of 97/23/EC.
B1410 - Waterloo
Signature
Sales Director
DX235LCR 0-1
0-2 DX235LCR
1Safety
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.
Please respect the importance of taking responsibility for your

own safety, and that of other people who may be affected by
your actions.
The safety information on the following pages is organized into
the following sections:
1. "Safety Decals" on page 1-4
2. "Visibility Information" on page 1-18
3. "Summary of Safety Precautions for Lifting in Digging
Mode" on page 1-20
4. "Unauthorized Modifications" on page 1-21
5. "General Hazard Information" on page 1-21
6. "Before Starting Engine" on page 1-30
7. "Machine Operation" on page 1-35
8. "Maintenance" on page 1-43
9. "Battery" on page 1-52
10. "Towing" on page 1-54
11. "Shipping and Transportation" on page 1-55
12. "Excavator Rated Lift Capacity Tables" on page 1-56
DX235LCR Safety
1-1
WARNING
Improper operation and maintenance of this machine can
be hazardous and could result in serious injury or death.
Operator and maintenance personnel should read this
manual thoroughly before beginning operation or
maintenance.
Keep this manual in the storage compartment to the rear of
the operator's seat, and have all personnel involved in
working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the
machine can cause a serious accident, if they are not done
in a manner described in this manual.
The procedures and precautions given in this manual apply
only to intended uses of the machine.
If you use your machine for any unintended uses that are
not specifically prohibited, you must be sure that it is safe
for any others. 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
country or purchased from someone in another country, it
may lack certain safety devices and specifications that are
necessary for use in your country. If there is any question
about whether your product complies with the applicable
standards and regulations of your country, consult
DOOSAN or your DOOSAN distributor before operating the
machine.
SAFETY ALERT SYMBOL

Be Prepared - Get to Know All Operating and Safety
Instructions.
This is the Safety Alert Symbol. Wherever it appears in this
manual or on safety signs on the machine you must be alert
to the potential for personal injury or accidents. Always
observe safety precautions and follow recommended
procedures.
Safety DX235LCR
1-2
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"
symbol.
CAUTION
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in minor or moderate injury. It may
also be used to alert against a generally unsafe practice.
WARNING
indicates potential threat of a hazardous situation that, if
not avoided, could result in serious injury or death. It may
also be used to alert against highly unsafe practice.
DANGER
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may detonate or explode if handled or treated carelessly.
Other Signal Words

In addition to safety signal words, the following signal words are
used to indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.
NOTE: The word "NOTE" identifies information for effective

use.
DX235LCR Safety
1-3
SAFETY DECALS
Safety decals are attached to the machine to alert the operator
or maintenance person about potential hazards, the
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. Please become familiarized with all safety decals and
their messages.
Make sure that all the safety decals are in their correct location
and legible. Clean or replace the safety decals if they are
damaged, missing, or the texts and pictorials are not legible.
When you clean the safety decals, use a soft cloth, water, and
soap. Do not use solvent, gasoline, or other harsh chemicals to
clean the safety decals because this could loosen the adhesive
that secures the decals to the machine. Remember, if a safety
decal is attached to a part that is replaced, install a new safety
decal on the replacement part.
This machine uses safety decals with and without text. The type
and number of safety decals can vary depending upon
geographical regions and machine models.
Safety Decals With Text

Safety decals with text consist of a signal word, pictorial and a
text message panel. In some cases, a pictorial panel may not be
part of the safety decal.
Safety DX235LCR
1-4
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. The Hazard
safety sign panel uses a black triangular band and a pictorial to Panel
identify the hazard and the potential consequences of the failure
to follow instructions. The safety information panel uses
pictorials and/or prohibition signs to identify the actions
necessary to avoid the hazard.
Avoidance
Panel
Horizontal Configuration
Hazard Avoidance
Panel Panel
FG018723
Figure 1
DX235LCR Safety
1-5
Information and Location for Safety Decals
18 24 21 15 1
14
3 3
23 23
EX1402438
Figure 2
Safety DX235LCR
1-6
Information and Location for Safety Decals (Continued)
4 6 5
11
7, 8
12
13 4 17
10
22 9 22
EX1402439
Figure 3
DX235LCR Safety
1-7
1. 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. Check for overhead
or underground lines before operating.
• Secure and lock front window when it is in raised
position.
• Attachment interference can cause death, serious
injury or machine damage. Check attachment to
machine clearance through full working cycle
before operation.
• Keep bystanders out of swing area and travel
path and always look in the travel direction.
• Ensure mirrors and rear view camera are clean
and working properly.
• Never operate machine from outside the
operator's position.
• TO LEAVE THE EXCAVATOR:
1) Lower the attachment and dozer blade (if
equipped) to the ground and make sure all
controls are in neutral.
2) Stop engine and remove key.
3) Lower safety lever to LOCK position.
Safety DX235LCR
1-8
2. Warning Tag - "Do Not Operate" (950205-03802)
WARNING
• Stop engine and remove key.
• Attach "DO NOT OPERATE" warning tag to the
controls before servicing the machine.
• Do not operate when performing inspection or EX1301177
maintenance.
3. Keep Bystanders Away (950205-03803)
WARNING
• Keep out of swing area and travel path.
• Always look in the travel direction.
• Make sure swing area is clear of bystanders and
objects.
4. Hot Pressurized Fluid (950205-03781)
WARNING
HOT PRESSURIZED FLUID CAN CAUSE
SERIOUS BURNS
• Do not loosen or open cap when hot.
EX1301180
• Before opening:
1) Turn engine off.
2) Allow machine to cool.
3) Tip cap and open slowly to relieve pressure.
5. Entanglement in Rotating Parts (950205-03791)
WARNING
ROTATING PARTS CAN CAUSE DEATH OR
SERIOUS INJURY
Keep away from belt and rotating parts. Stop engine
before servicing. EX1301181
DX235LCR Safety
1-9
6. 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
7. Battery Explosion (950205-03785)
WARNING
• Read and follow instructions in Operation &
Maintenance Manual for battery maintenance.
• Keep arcs, sparks, flames, and lighted tobacco
away.
• Do not store metal tools or flammable materials
on or around batteries.
• Wear safety goggles and rubber gloves when EX1301183
working with batteries.
• If battery acid contact occurs:
1) Flush your skin with water immediately and
apply baking soda or lime to neutralize the
acid.
2) Flush your eyes with water for 10 - 15
minutes.
3) Get medical attention immediately.
8. Battery Disconnection (950205-03784)
IMPORTANT
AVOID ELECTRICAL COMPONENT DAMAGE
Disconnecting the battery while the engine is running
can cause damage to electrical components.
Disconnect battery only when the engine is turned
OFF.
Safety DX235LCR
1-10
9. 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.
• Bleed off pressure slowly and keep body away
from grease valve.
• Wear eye protection.
• Read and follow instructions in Operation &
Maintenance Manual for more information on
track adjustment.
10. Crush Hazard (950205-03805)
WARNING
Stay clear of the boom, arm, and attachment.
EX1301186
11. Pressurized Gas and Fluid (950205-03782)
WARNING
• Heat or impact can cause the accumulator to
explode.
• Keep away from flame. EX1301187
• Do not weld on or drill into accumulator.
DX235LCR Safety
1-11
12. Fall Hazard (950205-03783)
WARNING
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. Emergency Exit (950205-03810)
IMPORTANT
If primary exit is blocked, use glass breaking tool to
break glass for secondary exit.
EX1301190
Safety DX235LCR
1-12
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 for details regarding the work levers
(joysticks) control functions.
BHL Control Pattern (US Only) (950205-03868)
WARNING
AVOID INJURY OR DEATH
Read and understand the Operation & Maintenance
Manual for more information.
Refer to "Operating Instructions" section of this
EX1301192
manual for details regarding the work levers
(joysticks) control functions.
16. Impact Hazard (Optional) (950205-03963)
WARNING
• Activating the Intelligent Floating Boom Control EX1301193
with the tracks raised up can cause the machine
to drop suddenly.
• Do not activate Intelligent Floating Boom Control
when tracks are raised.
• Do not raise tracks when control is activated.
Refer to "Intelligent Floating Boom Control (Optional)"
section of this manual for more information.
DX235LCR Safety
1-13
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
• Do not weld on or drill holes in the protective
structure.
• Replace ROPS, if damaged or modified.
950205-03861
EX1301197
Safety DX235LCR
1-14
19. Falling Object (Optional) (950205-03786)
WARNING
UNSUPPORTED DOOR CAN FALL CAUSING
DEATH OR SERIOUS INJURY
• To open door:
1) Hold door firmly.
2) Lift door slowly until locking device
engages.
• To close door:
EX1301198
1) Hold door firmly.
2) Press locking device to disengage.
3) Lower door slowly.
DX235LCR Safety
1-15
20. Hydraulic Oil Check (Optional) 
(950205-06281, 950205-03965, 950205-06282)
IMPORTANT
INCORRECT OIL LEVEL OR INCORRECT FLUID CAN
CAUSE HYDRAULIC SYSTEM DAMAGE 32
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.
950205-06281
EX1505097
EX1505098
68
950205-06282
EX1505099
Safety DX235LCR
1-16
21. Hydraulic Breaker (Optional) (950205-03964)
IMPORTANT
AVOID HYDRAULIC SYSTEM DAMAGE
To adjust breaker impact, see 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.
EX1301203
24. Electric Welding Attention (950212-02440)
IMPORTANT
Electrical welding on the frame can damage the
engine's electronic control unit (ECU).
950212-02440
EX1402396
DX235LCR Safety
1-17
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. If a
machine is moved or sold into another region or
marketplace, it is the owner's responsibility to make
sure it complies with all regulations.
2 1. Mirror
2. Rear View Camera
1 1 FG016033
Figure 4
WARNING
Failure to check for and clear people from the surrounding
area of a machine could result in serious injury or death.
The operator should make sure that visual aids (mirrors and
camera(s)) are in proper working condition. Look for any
possible blind spots.
Your machine may be equipped with visual aids; mirrors or

cameras, but even with these aids, there still may be blind spots
which cannot be seen from the operator's seat, so always be
careful when operating.
Adjust the visual aids for the best visibility criteria for all areas
around the machine.
Safety DX235LCR
1-18
When swinging or backing up, press button to change display
mode on monitor so you can check rear and side of machine.
Before moving the machine, look around the work site through
mirrors and monitor to confirm that no one is around the
machine.
While operating or traveling in places with poor visibility, and if it
is impossible to confirm the condition of the work site, or if an
obstacle is in the area around the machine, there can be a
danger that the machine may suffer damage or operator or
others may suffer serious personal injury.
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
• If the visibility cannot be sufficiently assured, use a
flagman. The operator should pay careful attention to the
signals and follow the instructions of the flagman.
• Signals should only be given by one flagman.
• When working in dark places, turn "ON" work lights and
front lights on the machine. Set up additional lighting in the
area.
• Stop operations if there is poor visibility, such as fog, snow,
rain, or sandstorms.
• Check mirrors and rear view camera (optional) lens on
machine before starting operations. Clean off any dirt and
adjust view to ensure good visibility.
When operating or traveling during poor visibility conditions, and
especially in a large machine, strictly adhere to the above
guidelines.
NOTE: Refer to ISO 5006 for additional guidelines and
information.
It may not be possible to adjust all visual aids to see all the way
around the machine. Therefore, additional precautions must be
taken to ensure the safe operation of the machine.
NOTE: Larger machines are more likely to have blind spots.
NOTE: Refer to ISO 5006 for weight class information.
DX235LCR Safety
1-19
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.
To lift safely while in Digging Mode, the following items must be

evaluated by the operator and the work site crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Tag lines on opposite sides of the load can be very helpful in
keeping a suspended load secure, if they are anchored safely to
control points on the ground.
WARNING
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind gusts
are more than 48.3 km/h (30 MPH). Be prepared for any wind
gust when working with loads that have a large surface
area.
Always engage the "Digging Mode" control on the Instrument

Panel before using the excavator for lifting work.
Safety DX235LCR
1-20
WARNING
If you need more information or have any questions or
concerns about safe operating procedures or working the
excavator correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.
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
the time to replace fasteners, bolts or nuts with the correct
replacement parts could lead to a condition where the safety of
critical assemblies are dangerously compromised.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgment in
emergencies and can cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
DX235LCR Safety
1-21
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.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.
Inside Operator's Cabin

When entering the operator's cabin, always remove all mud and
oil from the soles of your shoes. If you operate the travel pedal
with mud or oil stuck to your shoes, your foot may slip and this
can cause a serious accident.
After using the ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to close the
ashtray. If the ashtray is left open, there is a danger of fire.
Do not stick suction pads to the window glass. Suction pads act
as a lens and can cause fire.
Do not leave lighters laying around the operator's cabin. If the
temperature inside the operator's cabin becomes high, there is a
danger that lighter may explode.
Do not use cellular telephones inside the operator's cabin when
driving or operating the machine. There is a danger that this may
lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cabin.
To ensure safety, do not use the radio or music headphones
when operating the machine. There is a danger that this may
lead to a serious accident.
When operating the machine, do not put your hands or head out
of the window.
When standing up from the operator's seat, always place safety
lock lever securely in the "LOCK" position. If you accidentally
touch the work equipment levers when they are not locked, the
machine may suddenly move and cause serious injury or
damage.
When leaving the machine, completely lower the work
equipment to the ground, set safety lock lever to "LOCK"
position and stop engine. Use the key to lock all the equipment.
Always remove key and take it with you.
Safety DX235LCR
1-22
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.
While working on the machine, never use inadequate tools.
They could break or slip, causing injury, or they may not HAOA020L
adequately perform intended functions. Figure 5
Breathing Masks, Ear Protection May Be

Required
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause disabling or
permanent injuries.
NOTE: The equivalent continuous A-weighted sound
pressure level at the workstation for this machine is
71 dB(A).
Measurement is obtained on a dynamic machine
following the procedures and cabin conditions as
described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the
machinery for this machine is 101 dB(A).
Measurement is obtained on a dynamic machine with
the procedures as described in 2000/14/EC.
Vibration Level Information

Hands/Arms: The weighted root mean square acceleration to
which the hands/arms are subjected, is less than 2.5 m/s2.
Whole body: The weighted root mean square acceleration to
which the whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standard:
ISO 2631/1. ISO 5349, and SAE J1166.
DX235LCR Safety
1-23
Recommendations for Limiting Vibrations
1. Select the right machine, equipment and attachments for a
particular application.
2. 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.
• Inspect and maintain the suspension and adjustment
mechanisms of the seat regularly.
3. Check that the machine is properly maintained.
• Tire pressure, brakes, steering, linkages, etc.
4. Steer, brake, accelerate, shift gears, move the
attachments and load the attachments smoothly.
5. Adjust the machine speed and travel path to reduce the
vibration level.
• Slow down if it is necessary when traveling through
rough terrain.
• When driving machine, avoid obstacles and
excessive rough terrain.
6. Keep the machine on terrain where working and traveling
conditions are good.
• Remove any large rocks or obstacles.
• Fill any ditches and holes.
• Provide machines for and schedule time to maintain
good terrain conditions.
7. Travel over longer distances (e.g. on public roads) at
adjusted (medium) speed.
• Always adjust the speed to prevent bouncing.
Safety DX235LCR
1-24
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. In particular, never get on or
off a moving machine. These actions may lead to serious injury.
When getting on or off the machine, always face the machine,
and maintain three-point contact (both feet and one hand or one
foot and both hands) with the handrails, steps, and track shoes
to ensure that you support yourself securely.
Never hold any control levers when getting on or off the
machine.
Apply the door lock securely. If you grip the handrail inside the
door when moving on top of the track shoes, and the door lock is
not applied securely, the door may move and cause you to fall.
Use the points marked by arrows in the diagram when getting on
or off the machine.
FG015869
Figure 6
Fuel, Oil and Hydraulic Fluid Fire Hazards

Fuel, oil and antifreeze will catch fire if it is brought close to a
flame. Fuel is particularly flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the machine only in
a well ventilated area. The machine must be parked with
controls, lights and switches turned "OFF". The engine must be
"OFF" and any flames, glowing embers, auxiliary heating units
or spark causing equipment must be extinguished, turned "OFF"
and/or kept well clear of the machine.
Static electricity can produce dangerous sparks at the fuel filling
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep the tip of the fuel nozzle in
constant contact with the neck of the fuel filling nozzle, to
ARO1050S
provide a ground.
Figure 7
Keep fuel and other fluid reservoir caps tight and do not start the
engine until caps have been secured.
DX235LCR Safety
1-25
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. Always wait for the temperature to go
down, and follow the specified procedures when carrying out
these operations.
HAOA050L
Figure 8
To prevent hot coolant from spurting out, stop engine, wait for
the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, stop engine, wait for the oil
to cool, then loosen the cap slowly to relieve the pressure.
HAOA060L
Figure 9
Asbestos Dust Hazard Prevention

Asbestos dust can be HAZARDOUS to your health if it is
inhaled. Materials containing asbestos fiber can be present on
work site. Breathing air that contains asbestos fiber can
ultimately cause serious or fatal lung damage. To prevent lung
damage from asbestos fiber, observe following precautions:
• Use a respirator that is approved for use in an
asbestos-laden atmosphere.
• Never use compressed air for cleaning.
ARO1770L
• Use water for cleaning to keep down the dust. Figure 10
• Work on the machine or component with the wind at your
back whenever possible.
• Always observe any regulations related to the work site
and working environment.
Safety DX235LCR
1-26
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.
If going between movable parts is necessary, always position
and secure the work equipment so it cannot move.
HDO1010L
Figure 11
Fire Extinguisher and First Aid Kit

As a precaution if any injury or fire should occur, always do the
following.
• Be sure that fire extinguishers have been provided and
read the labels to ensure that you know how to use them. It
is recommended that an appropriately sized (2.27 kg [5 lb]
or larger) multipurpose "A/B/C" fire extinguisher be
mounted in the cabin. Check and service the fire
extinguisher at regular intervals and make sure that all
work site crew members are adequately trained in its use. HDO1009L
Figure 12
• Provide a first aid kit in the storage compartment and keep
another at the work site. Check the kit periodically and
make any additions if necessary.
• Know what to do in case of injury from fire.
• Keep emergency numbers for doctor, ambulance service,
hospital and fire department near your telephone.
If the machine catches fire, it may lead to serious personal injury
or death. If a fire occurs during operation, escape from the
machine as follows:
• Turn the starter switch to "O" (OFF) position and stop
engine.
• If there is time, use the fire extinguisher to put out as much
of the fire as possible.
• Use the handrails and steps to escape from the machine.
The above is the basic method for escaping from the machine,
but changing the method may be necessary according to the
conditions, so carry out practice drills at the work site.
DX235LCR Safety
1-27
Protection from Falling or Flying Objects
On work sites where there is a danger that falling or flying
objects may hit the operator's cabin select a guard to match the
operating conditions to protect the operator.
Working in mines, tunnels, deep pits or on loose or wet surfaces
could produce danger of falling rock or hazardous flying objects.
Additional protection for the operator's cabin could be required in
the form of a FOPS (Falling Object Protective Structure) or
window guards.
HAOA110L
Figure 13
Never attempt to alter or modify any protective structure

reinforcement system, by drilling holes, welding, remounting or
relocating fasteners. Any serious impact or damage to the
system requires a complete integrity reevaluation.
Reinstallation, recertification and/or replacement of the system
may be necessary.
Contact your DOOSAN distributor for available safety guards
and/or recommendations to prevent danger of getting hit by
objects that could strike the operator's cabin. Make sure that all
other work site crew members are kept well away from the
excavator and safe from possible hazards. HAOA100L
Figure 14
For breaker operation, install a front guard and apply a
laminated coating sheet to the front glass. Contact your
DOOSAN distributor for recommendations.
When carrying out demolition or cutting operation, install a front
guard and top guard, and apply a laminated coating sheet to the
front glass.
When working in mines or quarries where there is a danger of
falling rock, install FOPS (Falling Objects Protective Structure)
and apply a laminated coating sheet to the front glass.
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
that owners may wish to install on their machines, please
contact DOOSAN for authorization and approval of attachments,
and their compatibility with optional kits.
Safety DX235LCR
1-28
Accumulator
The pilot control system is equipped with an accumulator. For a
brief period of time after the engine has been stopped,
accumulator will store a pressure charge that may enable
hydraulic controls to be activated. Activation of any controls may
enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the
hydraulic pressure in the system must be released as described
in "Handling of Accumulator" on page 4-77.
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions:
• Do not drill or make any holes in the accumulator or
expose it to any flames, fire or heat source.
• Do not weld on the accumulator, or try attaching anything to it.
• 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.
Indoor Ventilation
Engine exhaust gases can cause fatal accidents, and
unconsciousness, loss of alertness, judgment and motor control
and serious injury.
Make sure there is adequate ventilation before starting the
engine in any enclosed area.
You should also be aware of open windows, doors or ductwork
where exhaust may be carried, or blown by the wind, exposing
others to danger. ARO1770L
Figure 15
Emergency Exit
This machine 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 that requires the breaking of glass to exit from the
cabin. Grip the handle firmly and use the sharp point to break
the glass.
WARNING
FG014380
AVOID DEATH OR SERIOUS INJURY Figure 16
Protect your eyes when breaking the glass.
DX235LCR Safety
1-29
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. If there is a lot of dust
and sand on the work site, spray water before starting
operations.
If you need to operate on a street, protect pedestrians and cars
by designating a person for work site traffic duty or by erecting
fences and posting "No Entry" signs around the work site.
Erect fences, post "No Entry" signs, and take other steps to
prevent people from coming close to or entering the work site. If
people come close to a moving machine, they may be hit or
caught by the machine, and this may lead to serious personal
injury or death.
Waterlines, gas lines, phone lines and high-voltage electrical
lines may be buried under the work site. Contact each utility and DANGER
No Entry
identify their locations. Be careful not to damage or cut any of
FG015870
these lines.
Figure 17
Check the condition of the riverbed, and the depth and flow of
the water before operating in water or crossing a river. NEVER
work in water that is more than the permissible water depth.
Any object in vicinity of boom could represent a potential hazard,
or cause the operator to react suddenly and cause an accident.
Use a spotter or signal person when working near bridges,
phone lines, work site scaffolds, or other obstructions.
FG015871
Figure 18
Minimum levels of insurance coverage, work permits or

certification, physical barriers around the work site or restricted
hours of operation may be mandated by governing authorities.
There may also be regulations, guidelines, standards or
restrictions on equipment that may have to be followed for local
requirements. There may also be regulations related to
performing certain kinds of work. If there is any question about
whether your machine and work site complies with the
applicable standards and regulations, contact your local
authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine to escape.
Avoid operating your machine to close to the edge of cliffs, FG015872
overhangs, and deep ditches. The ground may be weak in such Figure 19
areas.
If the ground collapses, the machine could fall or tip over
resulting in serious injury or death.
Safety DX235LCR
1-30
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.
Checks Before Starting Engine

Every day before starting the engine for the first time, carry out
the following checks. If these checks are not carried out
properly, there is a danger of serious injury.
Remove all wood chips, leaves, grass, paper and other
flammable materials accumulated in the engine compartment
and around the battery. They could cause a fire. Remove any
dirt from the window glass, mirrors, handrails, and steps.
Do not leave tools or spare parts laying around in the operator's
cabin. The vibration of the machine when traveling or during
operations can cause them to fall and damage or break the
control levers or switches. They may also get caught in the gap
of the control levers and cause the work equipment to
malfunction or move dangerously. This may lead to unexpected
accidents.
Check the coolant, fuel, and hydraulic tank oil levels, and check
for clogged air cleaner and damage to the electrical wiring.
Adjust the operator's seat to a position where it is easy to
operate the machine, and check the seat belt and mounts for
damage and wear.
Check the operation of the gauges and the angle of the mirrors,
and check that safety lever is in "LOCKED" position.
If any abnormalities are found in the above checks, carry out
repairs immediately.
DX235LCR Safety
1-31
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.
Look around the work site area for potential hazards, people or
property that could be at risk while operation is in progress.
NEVER start the engine if there is any indication that
maintenance or service work is in progress, or if a warning tag is
attached to controls in the cabin.
A machine that has not been used recently, or is being operated
in extremely cold temperatures, could require a warm-up or
maintenance service before start-up.
Check gauges and monitor displays for normal operation before
starting the engine. Listen for unusual noises and remain alert
for other potentially hazardous conditions at the start of the work
cycle.
Do not short-circuit the starting motor to start the engine. This is
not only dangerous, but may also damage the machine.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
Safety DX235LCR
1-32
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. Do not let anyone near the machine when carrying
out the checks.
• Check the operating condition of the equipment, and the
movement of the bucket, arm, boom, travel, and swing
systems.
• Check the machine for any abnormal noise, vibration, heat,
smell, or abnormality with the gauges. Check also for
leakage of air, oil, and fuel.
• If any abnormality is found, repair the problem
immediately. If the machine is used without repairing the
problems, it may lead to unexpected injury or failure.
• Clear all personnel from directly around machine and from
the area.
• Clear all obstacles from the machine's path. Beware of
hazards.
• Be sure that all windows are clean. Secure the doors and
the windows in the open position or in the shut position.
• Adjust the rearview mirrors for best visibility close to the
machine. Make sure that horn, the travel alarm (if
equipped), and all other warning devices are working
properly.
• Fasten the seat belt securely.
• Warm up the engine and hydraulic oil before operating
machine.
• Before moving the machine, check undercarriage position.
The normal travel position is with idler wheels to the front
under the cabin and the drive sprockets to the rear. When
the undercarriage is in the reversed position, the travel
controls must be operated in opposite directions.
DX235LCR Safety
1-33
Seat Belt
Check seat belt daily for correct function.
Inspect seat belt system more often if machine is exposed to
severe environmental conditions or applications. Conduct the
following inspections and replace seat belt system as
necessary:
1. Check webbing. If system is equipped with a retractor, pull
webbing completely out and inspect full length of webbing.
Look for cuts, wear, fraying, dirt and stiffness.
2. Check buckle and latch for correct operation.
3. Make sure latch plate is not excessively worn, deformed or
buckle is not damaged or casing is broken.
4. Check retractor web storage device (if equipped) by
extending webbing and checking that it spools out and
retracts correctly.
5. Check webbing in areas exposed to ultraviolet (UV) rays
from sun or extreme dust or dirt. 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
Failure to properly inspect and maintain seat belt and
seat belt system can cause lack of operator restraint
and can result in death or serious injury.
Before fastening seat belt, check that there is no
problem in belt mounting bracket. If it is worn or
damaged, replace seat belt. Fasten seat belt so it is not
twisted.
Always wear seat belt when operating machine.
Safety DX235LCR
1-34
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. HAOA190L
• Sound the horn to warn people in the area. Figure 20
• Check that there is no one in the area around the machine.

There are blind spots behind the machine, so if necessary,
swing the upper structure to check that there is no one
behind the machine before traveling in reverse.
• When operating in areas that may be hazardous or have
poor visibility, designate a person to direct work site traffic.
• Ensure that no unauthorized person can come within the
turning radius or direction of travel.
Be sure to observe the above precautions even if a travel alarm
or mirrors are installed.
DX235LCR Safety
1-35
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.
Do not change selected travel mode (FAST/SLOW) while
traveling.
40 ~ 50 cm (16 ~ 20 in.)
Fold in work equipment so the outer end of the boom is as close
to the machine as possible, and is 40 - 50 cm (16 - 20 in)
Incorrect
aboveground.
Never travel over obstacles or slopes that will cause the
machine to tilt severely. Travel around any slope or obstacle that
causes the machine to tilt 10 degrees or more to the right or left,
or 30 degrees or more from front to rear.
Do not operate the steering suddenly. The work equipment may
FG015873
hit the ground and cause the machine to lose its balance, and
this can damage the machine or structures in the area. Figure 21
When traveling on rough ground, travel at low speed, and avoid

sudden changes in direction.
Always keep to the permissible water depth. Permissible water
depth is to the centerline of the upper track rollers.
When traveling over bridges or structures on private land, check
first that bridge or structure can withstand the weight of the
machine. When traveling on public roads, check with the local
authorities and follow their instructions.
Safety DX235LCR
1-36
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. 20 -
30 c
m
On hills, banks or slopes, carry the bucket approximately 20 - 30
cm (8 - 12 in) above the ground. In case of an emergency,
quickly lower the bucket to the ground to help stop the machine.
Do not travel on grass, fallen leaves, or wet steel plates. Even
slight slopes can cause the machine to slip to the side, so travel
at low speed and make sure that the machine is always traveling
directly up or down the slope.
Avoid changing travel direction on a slope. This could result in
tipping or sideslipping of the machine.
When possible, operate the machine up slopes and downslopes. cm
- 30
Avoid operating the machine across the slope, when possible. 20
FG015874
Figure 22
DX235LCR Safety
1-37
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.
Working heavy loads over loose, soft ground or uneven, broken
terrain can cause dangerous side load conditions and possible
tip over and injury. Travel without a load or a balanced load may
also be hazardous.
Never rely on lift jacks or other inadequate supports when work
is being done. Block tracks fore and aft to prevent any
movement. FG015876
Figure 24
When using the machine, to prevent accidents caused by

damage to the work equipment and overturning because of an
excessive load, do not use the machine in excess of its ability (in
terms of the maximum load and stability determined by the
structure of the machine).
When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death. Investigate the configuration and ground
conditions of the work site beforehand to prevent the machine
from falling and to prevent the ground, stockpiles, or banks from
collapsing. FG015877
Figure 25
Safety DX235LCR
1-38
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:
• When working in dark areas, attach working lights and
front lights to the machine. If necessary, set up lighting at
the work site.
• Stop operations when the visibility is poor, such as in fog,
mist, snow, and rain. Wait for the visibility to improve to a
level which causes no problems for the operation.
To avoid hitting the work equipment, always do the following:
• When working in tunnels, on bridges, under electrical
wires, or when parking the machine or carrying out other
operations in places with limited height, be careful not to hit
the bucket or other parts.
• To prevent collisions, operate the machine at a safe speed
when working in confined spaces, indoors, or in crowded
areas.
• Do not pass the bucket over the heads of workers or over
the operator's cabin of dump truck. FG015878
Figure 26
Avoid High-voltage Cables

Serious injury or death can result from contact or proximity to
high-voltage electrical lines. The bucket does not have to make
physical contact with power lines for current to be transmitted.
Use a spotter and hand signals to stay away from power lines
not clearly visible to the operator.
Voltage Minimum Safe Distance

6.6 kV 3 m (9' 10")
FG015879
33.0 kV 4 m (13' 1")
Figure 27
66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")
Use these minimum distances as a guideline only. Depending

upon the voltage in the line and atmospheric conditions, strong
current shocks can occur with the boom or bucket as faraway as
4 - 6 m (13 - 20 ft.) from the power line. Very high voltage and
rainy weather could further decrease that safety margin.
NOTE: Before starting any operation near power lines (either
aboveground or buried cable type), you should
always contact the power utility company directly and
work out a safety plan with them.
DX235LCR Safety
1-39
Roll Over Protective Structure (ROPS)
The operator's cabin is a ROPS certified structure for protecting
the seat-belted operator. It absorbs the impact energy of a
rollover impact. Do not allow machine weight (mass) to exceed
certified value on certification plate. If weight is exceeded, the
ROPS structure will not be able to fulfill its safety function.
Do not increase machine weight beyond certified value by
modifying machine or by installing attachments on machine. If
weight limit of protective equipment is exceeded, protective
equipment will not be able to protect operator, and operator may
suffer injury or death. Always observe the following:
• This machine is equipped with a protective structure. Do
not remove protective structure and carry out operations
without it.
• Never modify the operator’s 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
operator may suffer serious injury or death.
• When protective structure is damaged or deformed by
falling objects or by rolling over, its strength will be reduced
and it will not be able to properly fulfill its function. In these
cases, always contact your DOOSAN distributor for advice.
Never repair a ROPS cabin.
• Always wear your seat belt when operating machine.
ROPS Certification
This DOOSAN excavator has an operator’s cabin that meets
ROPS requirements. The seat belt must be worn for rollover
protection.
The ROPS certification plate (Figure 28) is found on the left side
of the cabin on most models. It may vary slightly in its location
on some models.
Check the ROPS cabin, mounting, and hardware for damage.
Never modify the ROPS cabin. Replace the cabin and hardware EX1300529
if damaged. See your DOOSAN dealer for parts. Figure 28
ROPS  Roll-over Protective Structure complies with
ISO 12117-2:2008, EN 13531: 2001.
WARNING
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.
Safety DX235LCR
1-40
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.
1
When using a breaker, be sure to install the front window
protection guard (1, Figure 29).
FG014374
Figure 29
In a work site where falling rocks can cause damage and

possibly crush personnel, or in a mining operation, be sure to
install the falling object protective structure (2, Figure 30).
Be sure to install any other additional protective structures
required for work site conditions.
When the falling object protective structure is installed, and the
front window needs to be cleaned, loosen the bolts marked with 2
an arrow (3, Figure 30). Be sure to tighten bolts when done.
Operate Carefully on Snow, Ice and in Very

Cold Temperatures
In icy cold weather avoid sudden travel movements and stay
away from even slight slopes. The machine could skid off to one
side very easily.
Snow accumulation could hide or obscure potential hazards.

Use care while operating or while using the machine to clear
snow.
3
Warming up the engine for a short period may be necessary, to 3 3
avoid operating with sluggish or reduced working capacity. The FG016057
jolting shocks and impact loads caused by bumping or Figure 30
bottoming the boom or attachment are more likely to cause
severe stress in very cold temperatures. Reducing work cycle
rate and workload may be necessary.
When the temperature rises, frozen road surfaces become soft,

and machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare

hands. If you touch a metal surface in extremely cold weather,
your skin may freeze to the metal surface.
DX235LCR Safety
1-41
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. This operation is
dangerous.
If the machine has to be used on a slope, pile the soil to make a
FG015880
platform that will keep the machine as horizontal as possible.
Figure 31
In addition, lower the bucket as far as possible, keep it pulled
into the front, and keep the swing speed as low as possible.
Parking Machine
Avoid making sudden stops, or parking the machine wherever it
happens to be at the end of the workday. Plan so the excavator 120
will be on firm and level ground away from traffic and away from
high walls, cliff edges and any area of potential water
accumulation or runoff. If parking on inclines is unavoidable,
block the crawler tracks to prevent movement. Lower the bucket Block
or other working attachment completely to the ground, or to an
overnight support saddle. There must be no possibility of
unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or
lights, and put up any other necessary signs to ensure that
passing traffic can see the machine clearly. Park the machine so
the machine, flags, and fences do not obstruct traffic. Unlock
After the front attachment has been lowered to an overnight
storage position and all switches and operating controls are in
the "OFF" position, the safety lock lever must be set to Lock FG015881
"LOCKED" position. This will disable all pilot circuit control Figure 32
functions.
Always close the door of the operator's cabin.
Never Let Anyone Ride on Attachment

Never let anyone ride on any work attachment, such as the
bucket, crusher, grapple, or clamshell (grab bucket). There is a
potential danger of the person falling and suffering serious
injury.
ARO1310L
Figure 33
Safety DX235LCR
1-42
MAINTENANCE
Warning Tag
Alert others that service or maintenance is being performed and
tag operator's cabin controls – and other machine areas if
required – with a warning notice. OSHA mandated control lever
lockout can be made with any 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
Clean Before Inspection or Maintenance

Clean the machine before carrying out inspection and
maintenance. This prevents dirt from getting into the machine
and ensures safety during maintenance.
If inspection and maintenance are carried out when the machine
is dirty, it will become more difficult to locate the problems, and
there is a danger that you may get dirt or mud in your eyes or
that you may slip and injure yourself.
When washing the machine, do the following:
• Wear shoes with nonslip soles to prevent yourself from
slipping and falling on wet places.
• Wear safety glasses and protective clothing when washing
the machine with high-pressure steam.
• Take action to prevent touching high-pressure water and
cutting your skin or having mud fly into your eyes.
ARO1330L
• Do not spray water directly on electrical components
Figure 35
(sensors, connector). If water gets into the electrical
system, there is a danger that it will cause defective
operation and malfunction.
Pick up any tools or hammers that are laying in the workplace.
Wipe up any grease or oil or any other slippery substances, and
clean the area to make it possible to carry out the operation in
safety. If the workplace is left untidy, you may trip or slip and
suffer injury.
DX235LCR Safety
1-43
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
When checking fuel, oil, battery electrolyte, or window washing
fluid, always use lighting with antiexplosion specifications. If
such lighting equipment is not used, there is a danger of an
explosion.
If work is carried out in dark places without using lighting, it may
lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame instead of
lighting. There is a danger of fire. There is also danger that
HDO1040L
battery gas may catch fire and cause an explosion. Figure 37
Fire Prevention and Explosion Prevention

All fuels, most lubricants and some coolant mixtures are
flammable. Leaking fuel or fuel that is spilled onto hot surfaces
or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked containers
and away from all unauthorized persons.
Store oily rags and other flammable material in a protective
container.
Do not smoke while you refuel the machine or while you are in a
HDO1015I
refueling area.
Figure 38
Do not smoke in battery charging areas or in areas that contain
flammable material.
Clean all electrical connections and tighten all electrical
connections. Check the electrical wires daily for wires that are
loose or frayed. Tighten all lose electrical wires before you
operate the machine. Repair all frayed electrical wires before
you operate the machine.
Remove all flammable materials before they accumulate on the
machine.
Do not weld on pipes or on tubes that contain flammable fluids.
Do not flame cut on pipes or on tubes that contain flammable
fluids. Before you weld on pipes or on tubes or before you flame
cut on pipes or on tubes, clean the pipes or tubes thoroughly
with a nonflammable solvent.
Safety DX235LCR
1-44
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.
If the coolant level in the coolant recovery tank is below the
lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the eyes,
or the mouth.
Allow cooling system components to cool before you drain the
cooling system.
Hot oil and hot components can cause personal injury. Do not
allow hot oil or hot components to contact the skin.
Remove hydraulic tank filter plug only after the engine has been
stopped. Make sure that hydraulic tank filter plug is cool before
you remove it with your bare hand. Remove hydraulic tank filter
plug slowly to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel
system, or in the cooling system before you disconnect any
lines, fittings, or related items.
Batteries give off flammable fumes that can explode. haae2090
Figure 39
Do not smoke while you are checking the battery's electrolyte
levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses when you work on batteries.
DX235LCR Safety
1-45
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. Repairs must be performed by a qualified
welder. Welding operations, can create potential hazards,
including generation of gas, fire, or electric shock. Never let an
unqualified welder do welding.
A qualified welder must do the following:
• To prevent battery explosion, turn battery disconnect
switch to "OFF" position.
• Disconnect the connector between ECU and machine, and
the connector between ECU and engine.
• To prevent generation of gas, remove paint from location
of the weld.
• If hydraulic equipment, piping or component ports close to
them are heated, a flammable gas or mist could result in
an explosion or fire. To prevent this, protect and insulate
components from excessive heat.
• Do not weld on pipes or on tubes that contain flammable
fluids. Do not flame cut pipes or tubes that contain
flammable fluids. Before welding on pipes or tubes, or
before flaming cut pipes or tubes, clean them thoroughly
with a nonflammable solvent. Make sure pressure inside
pipes or tubes does not cause a rupture of the component
parts.
• If heat is applied directly to rubber hoses or piping under
pressure, they may suddenly break, so cover and insulate
them with a fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and make sure a fire
extinguisher is available.
Safety DX235LCR
1-46
Treatment for Electrical Welding on Body Structure
To prevent damage to ECU by electrical welding, please
observe the following procedures:
1. Open the side door (LH).
2. Detach the cover after loosening the bolts on the battery.
3. Detach the positive and negative terminal cables from the
battery.
4. Detach the undercover, and after that detach the connector
(1) from the ECU that are installed at the engine. FG000312
Figure 40
5. Proceed with welding.
6. After welding, carefully reassemble the connector.

7. Connect the battery terminal cables. 1
8. Reassemble the undercover under the engine.
9. Reassemble the cover over the battery.
10. Close the cover of the battery.
FG000335
Figure 41
Warning for Counterweight and Front

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. DOOSAN is not liable for any misuse.
Never remove counterweight or front attachment unless the
FG015882
upper structure is in-line with the lower structure.
Figure 42
Never rotate the upper structure once the counterweight or
front attachment has been removed.
DX235LCR Safety
1-47
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. Put up a fence around the
attachments and take other measures to prevent unauthorized HDO1041L
persons from entering. Figure 43
Precautions When Working on Machine

When carrying out maintenance operations on the machine,
keep area around your feet clean and tidy to prevent falls.
Always do the following:
• Do not spill oil or grease.
• Do not leave tools laying about.
• Watch your step when walking.
Never jump down from the machine. When getting on or off the
ARO1380L
machine, use the steps and handrails, and maintain a
Figure 44
three-point contact (both feet and one hand or both hands and
one foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when working on the
hood or covers, never use any area except the area equipped
with nonslip pads.
Lock Inspection Covers

When carrying out maintenance with the inspection cover open,
lock the cover securely in position with the lock bar.
If maintenance work is carried out with the inspection cover
open but not locked, there is a danger that it may suddenly close
and cause injury if there is a gust of wind.
Safety DX235LCR
1-48
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.
Stay clear of all rotating parts and moving parts.
Keep objects away from moving fan blades. The fan blades will
throw objects and the fan blades can cut objects.
Do not use a wire rope cable that is kinked or frayed. Wear
gloves when you handle a wire rope cable.
When you strike a retainer pin, the retainer pin might fly out. The
loose retainer pin can injure personnel. Make sure that area is
clear of people when you strike a retainer pin. To avoid injury to
your eyes, wear protective glasses when you strike a retainer
pin.
Track Tension Adjustments Require

Caution
Never turn out the track tension grease valve. To release
pressure from the crawler frame track tension assembly, you
should NEVER attempt to disassemble the track adjuster or
attempt to remove grease fitting or valve assembly.
Keep your face and body away from the valve. Refer to the track
adjustment procedure in the Operator and Maintenance Manual
or Shop Manual.
HAOA110L
Figure 45
Supports and Blocking for Work

Equipment
Do not allow weight or equipment loads to remain suspended.
Lower everything to the ground before leaving the operator's
seat.
Do not use hollow, cracked or unsteady wobbling supports.
Do not work under any equipment supported only by a lifting
jack.
HDO1042L
Figure 46
DX235LCR Safety
1-49
Action When Abnormality Is Found During
Inspection
If any abnormality is found during inspection, always carry out
repairs. In particular, if the machine is used when there are still
problems with the brake or work equipment systems, it may lead
to serious injury.
If necessary depending on the type of failure, please contact
your DOOSAN distributor for repairs.
Precautions with High-pressure Lines,

Tubes and Hoses X
When inspecting or replacing high-pressure piping or hoses,
check to verify that pressure has been released from the circuit.
Failure to release the pressure may lead to serious injury.
Always do the following:
• Wear protective glasses and leather gloves.
• Fluid leaks from hydraulic hoses or pressurized X
components can be difficult to see but pressurized oil has
enough force to pierce the skin and cause serious injury.
Always use a piece of wood or cardboard to check for
suspected hydraulic leaks. Never use your hands or
expose your fingers.
• Do not bend high-pressure lines. Do not strike
high-pressure lines. Do not install lines, tubes or hoses that
are bent or damaged.
• Make sure that all clamps, guards and heat shields are
installed correctly to prevent vibration, rubbing against
other parts, and excessive heat during operation.
– If any of the following conditions are found, replace HDO1045I
the part: Figure 47
– Damage or leakage from hose end.
– Wear, damage, cutting of covering, or exposure of
strengthening wire layer.
– Cover portion is swollen in places.
– There is twisting or crushing at movable parts of
hose.
– Foreign material is embedded in the covering.
– Hose end is deformed.
NOTE: Refer to "Hose In-service Lifetime Limit (European
Standard ISO 8331 and EN982 CEN)" on page 4-63,
for additional European regulations.
Safety DX235LCR
1-50
Waste Materials
Physical contact with used motor oil may pose a health risk.
X
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:
• Never dump waste oil in a sewer system, rivers, etc.
• Always put oil drained from your machine in containers. HAOA470L
Never drain oil directly onto the ground. Figure 48
• Obey appropriate laws and regulations when disposing of
harmful materials such as oil, fuel, solvent, filters, and
batteries.
DX235LCR Safety
1-51
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.
• When working with batteries, ALWAYS wear safety
glasses and rubber gloves.
• If you spill battery electrolyte on yourself or your clothes,
immediately flush the area with water.
• If battery electrolyte gets into your eyes, flush them
immediately with large quantities of water and see a doctor
at once.
• If you accidentally drink battery electrolyte, drink a large
quantity of water or milk, raw egg or vegetable oil. Call a
doctor or poison prevention center immediately.
• When cleaning the top surface of the battery, wipe it with a
clean, damp cloth. Never use gasoline, thinner, or any
other organic solvent or detergent.
HAAE2100
• Tighten the battery caps securely.
Figure 49
• If the battery electrolyte is frozen, do not charge the battery
or start the engine with power from another source. There
is a danger that battery may catch fire.
• When charging the battery or starting with power from
another source, let the battery electrolyte melt and check
that there is no leakage of battery electrolyte before
starting the operation.
• Always remove battery from the machine before charging.
Safety DX235LCR
1-52
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. This includes electrical switches on the battery
charger or boost starting equipment.
• When boost starting from another machine or vehicle do HAOA310L
not allow the two machines to touch. Wear safety glasses Figure 50
or goggles while required battery connections are made.
• 24 volt battery units consisting of two series connected
twelve volt batteries have a cable connecting one positive
terminal on one of the 12 volt batteries to a negative
terminal on the other battery. Booster or charger cable
connections must be made between the nonseries
connected positive terminals and between the negative
terminal of the booster battery and the metal frame of the
machine being boosted or charged. Refer to the procedure
and illustration in "Starting Engine With a Booster Cable"
on page 3-7 of this manual.
• Connect positive cable first when installing cables and
disconnect the negative cable first when removing them.
The final cable connection, at the metal frame of the
machine being charged or boost started, must be as
faraway from the batteries as possible.
DX235LCR Safety
1-53
TOWING
Precautions When Towing Cloth

If any mistake is made in the method of selecting or inspecting
the towing wire or in the method of towing, it may lead to serious
personal injury. Always do the following:
• Always use the method of towing given in this Operation
and Maintenance Manual. Do not use any other method.
• Use leather gloves when handling the wire rope. Towing Wire
• When carrying out the preparation work for towing with two
or more workers, determine the signals to use and follow
these signals correctly.
• Always fit the towing rope to the left and right hooks and
secure in position.
• 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
machine during the towing operation. Towing Wire
FG015010
Figure 51
• It is dangerous to carry out towing on slopes, so select a
place where the slope is gradual. If there is no place where
the slope is gradual, carry out operations to reduce the
angle of the slope before starting the towing operation.
• When towing a problem machine, always use a wire rope
with a sufficient towing capacity.
• Do not use a frayed, kinked rope or a rope with any loss of
diameter.
• Do not use the lightweight towing hook for towing another
machine.
Safety DX235LCR
1-54
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.
Partial disassembly or teardown of the excavator may be
necessary to meet travel restrictions or particular conditions at
the work site. See the Shop Manual for information on partial
disassembly.
Refer to the Transportation and Shipping section of this
Operation and Maintenance Manual for information on loading,
unloading and towing.
DX235LCR Safety
1-55
EXCAVATOR RATED LIFT
CAPACITY TABLES
WARNING
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.
When changing the hoses record the part numbers of the
hoses to factory log book. Figure 52
Do the service job under the company's serviceman.
WARNING
All rated lift capacities are based on the machine and the
load both remaining level at all times. DO NOT EXCEED THE
RATED LIFT CAPACITY. Lifting loads greater than those
shown in the rated capacity tables can cause catastrophic
equipment failure and/or structural collapse of the machine.
To operate safely the excavator must be on a firm, level and

uniformly supporting surface. The operator is expected to make
due allowance for all specific work site and lift related conditions,
and respond to changes in those conditions that could pose a
hazard. The following could all cause hazardous conditions and
accidents or injuries:
• Soft or uneven ground.
• Unlevel terrain.
• Side loads.
• Modifications or poor maintenance of the excavator.
• Failure to lift squarely over the end or over the side of the
machine.
When a load is in the air, the operator must remain alert.
• Avoid side loads that may be caused by uneven slings,
traveling with the load or swinging too quickly.
• The load can become unbalanced if the hook line is twisted
and starts to rotate. If the surface area of the load is large
enough, wind gusts can create side loads.
Safety DX235LCR
1-56
• 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. The operator and all work site personnel
must be thoroughly familiar with safety instructions and
procedures within this Operation and Maintenance Manual.
The following weight loads are in compliance with ISO 10567
and ISO applicable, recommended standards for hydraulic
excavators performing lifting operation on a firm supporting
surface. An asterisk (*) next to the lift rating indicates rated load
does not exceed 87% of hydraulic capacity. All other ratings
have been determined not to exceed 75% of tipping capacity.
Do not attempt to lift or hold any load that exceeds rated load
capacity at the specified distances (from the machine's rotation
centerline and height - see "lift radius" and "lift height" in the
reference drawing, Figure 53).
Lifting Radius
Centerline
of Rotation
Lifting
Point
Lifting
Point
Height
Ground Line (Machine Supporting Surface)
Figure 53
FG015898
The weight of slings and any auxiliary lifting device (and/or the
weight difference of any attachment heavier than standard
configuration) must be deducted from the rated lift capacity to
determine allowable net lifting load. The lift point must be on the
back of the bucket, as shown in Figure 53.
IMPORTANT
Select the Digging Mode switch on the Instrument Panel
before using the excavator for lifting work. Engine and
hydraulic oil should both be fully warmed up to operating
temperature before starting a lift.
DX235LCR Safety
1-57
Standard
Track Width 2.99 m 9 10 Track

A Boom 5.7 18 8
Arm 2.9 9 6
Bucket SAE 0.92 m3 (CECE 0.81 m3)
Shoe 600 mm (24 )
Counter Weight : 6,480 kg (14,286 Ib)
B
UNIT : 1,000 kg (1,000 Ib)
: Rating Over Front
: Rating Over Side or 360 degree
FG015898
Figure 54
Metric
A (m) 2 3 4 5 6 7 8 Max. Reach
A (m)
B (m)
8 *4.77 * *4.77 * *3.95 *3.95 @5.48
7 *5.46 *5.46 *4.66 *4.66 *3.75 *3.75 @6.43
6 *5.76 *5.76 *5.61 4.61 *4.06 3.46 *3.69 3.34 @7.13
5 *7.02 *7.02 *6.40 6.14 *5.97 4.48 *5.38 3.39 *3.73 2.88 @7.62
4 *17.47 *17.47 *11.08 *11.08 *8.62 8.49 *7.31 5.84 *6.51 4.30 5.62 3.29 *3.85 2.59 @7.96
3 *15.02 12.62 *10.49 7.86 *8.37 5.51 7.09 4.10 5.48 3.17 4.37 2.49 *4.05 2.40 @8.16
2 *7.98 *7.98 *12.16 7.31 9.31 5.19 6.87 3.91 5.34 3.04 4.29 2.42 4.09 2.30 @8.23
1 *7.79 *7.79 *13.23 6.94 9.02 4.94 6.68 3.74 5.22 2.93 4.22 2.35 4.07 2.26 @8.18
0 *9.50 *9.50 13.15 6.75 8.83 4.78 6.55 3.62 5.13 2.85 4.17 2.30 4.17 2.3 @8.00
-1 *8.70 *8.70 *11.88 11.06 13.06 6.68 8.73 4.69 6.47 3.55 5.08 2.80 4.4 2.43 @7.69
-2 *11.36 *11.36 *14.82 11.15 *12.92 6.69 8.71 4.68 6.45 3.53 5.08 2.80 4.84 2.67 @7.23
-3 *14.30 *14.30 *15.04 11.31 *11.89 6.78 8.77 4.73 6.50 3.58 5.64 3.12 @6.58
-4 *16.51 *16.51 *12.79 11.56 *10.27 6.94 *8.29 4.85 *7.07 4.00 @5.68
-5 *9.50 *9.50 *7.65 7.21 *6.96 6.26 @4.37
Safety DX235LCR
1-58
Feet
A (ft) 10 15 20 25 Max. Reach
A (ft)
B (ft)
25 *11.95 *11.95 *8.50 *8.50 @19.29
20 *12.73 *12.73 *12.13 9.89 *8.14 7.48 @23.20
15 *19.97 *19.97 *15.63 15.46 *13.54 9.45 *9.58 6.29 *8.31 6.04 @25.53
10 *31.98 27.23 *19.96 14.05 15.25 8.83 10.48 6.02 *8.91 5.31 @26.74
5 *17.46 *17.46 23.55 12.78 14.56 8.22 10.15 5.71 8.97 5.01 @26.98
0 *21.52 *21.52 22.7 12.07 14.08 7.79 9.91 5.49 9.18 5.08 @26.26
-5 *29.95 23.74 22.44 11.86 13.87 7.61 10.14 5.60 @24.51
-10 *32.56 24.21 22.63 12.02 13.98 7.71 12.54 6.95 @21.47
-15 *24.18 *24.18 *17.34 12.57 *15.58 10.97 @16.39
1. Ratings are based on SAE J1097.

2. Load point is the hook on the back of the bucket.
3. *Rated loads are based on hydraulic capacity.
4. Rated loads do not exceed 87% of hydraulic capacity or
75% of tipping capacity.
DX235LCR Safety
1-59
Option: Boom 5.7 m, Arm 2.4 m

A Boom 5.7 18 8
Arm 2.4 7 7
Shoe 600 mm (24 )
B
UNIT : 1,000 kg (1,000 Ib)
: Rating Over Front
FG015899
Figure 55
Metric
A (m) 2 3 4 5 6 7 Max. Reach
A (m)
B (m)
8 *6.40 *6.40 *5.44 *5.44 @4.81
7 *6.33 *6.33 *6.20 *6.20 *5.14 4.75 @5.88
6 *6.88 6.88 *6.46 6.25 *6.20 4.54 *5.06 3.78 @6.62
5 *9.64 *9.64 *8.02 *8.02 *7.09 6.03 *6.51 4.42 5.68 3.35 *5.12 3.22 @7.16
4 *13.16 *13.16 *9.67 8.26 *7.99 5.74 *7.02 4.25 5.58 3.27 4.94 2.87 @7.51
3 *11.50 7.66 *9.00 5.42 7.05 4.07 5.47 3.16 4.64 2.66 @7.73
2 *12.96 7.18 9.24 5.14 6.85 3.89 5.35 3.05 4.49 2.55 @7.80
1 13.34 6.91 9.00 4.94 6.69 3.75 5.25 2.96 4.47 2.52 @7.75
0 *8.57 *8.57 13.20 6.81 8.86 4.82 6.59 3.66 5.18 2.90 4.60 2.58 @7.56
-1 *8.95 *8.95 *12.28 11.33 13.19 6.79 8.8 4.77 6.54 3.62 5.15 2.88 4.91 2.74 @7.23
-2 *12.63 *12.63 *15.52 11.43 *12.48 6.84 8.82 4.79 6.55 3.63 5.49 3.07 @6.74
-3 *16.60 *16.60 *13.74 11.61 *11.19 6.96 8.92 4.87 6.64 3.71 6.58 3.68 @6.03
-4 *13.53 *13.53 *11.17 *11.17 *9.19 7.16 *7.34 5.04 *7.26 4.99 @5.03
Safety DX235LCR
1-60
Feet
A (ft) 10 15 20 25 Max. Reach
A (ft)
B (ft)
25 *13.84 *13.84 *11.66 *11.66 @17.25
20 *14.47 *14.47 *13.60 9.73 *11.15 8.49 @21.53
15 *23.85 *23.85 *17.40 15.13 *14.67 9.34 *11.43 6.73 @24.04
10 *21.63 13.78 15.16 8.76 10.47 6.02 10.24 5.88 @25.33
5 23.39 12.68 14.55 8.22 10.2 5.77 9.84 5.56 @25.57
0 *19.54 *19.54 22.78 12.17 14.16 7.88 10.14 5.68 @24.81
-5 *32.22 24.32 22.69 12.10 14.06 7.79 11.39 6.36 @22.96
-10 *29.78 24.86 *21.81 12.36 14.66 8.19 @19.67
-15 *19.96 *19.96 *15.46 14.66 @13.96

DX235LCR Safety
1-61
Option: Boom 5.7 m, Arm 2.9 m, Shoe 800 mm

A Boom 5.7 18 8
Arm 2.9 9 6
Shoe 800 mm (32 )
B
UNIT : 1,000 kg (1,000 Ib)
: Rating Over Front
FG015900
Figure 56
Metric
A (m) 2 3 4 5 6 7 8 Max. Reach
A (m)
B (m)
8 *4.77 *4.77 *3.95 *3.95 @5.48
7 *5.46 *5.46 *4.66 *4.66 *3.75 *3.75 @6.43
6 *5.76 *5.76 *5.61 4.72 *4.06 3.54 *3.69 3.42 @7.13
5 *7.02 *7.02 *6.40 6.28 *5.97 4.59 *5.38 3.48 *3.73 2.96 @7.62
4 *17.47 *17.47 *11.08 *11.08 *8.62 8.62 *7.31 5.98 *6.51 4.41 5.76 3.37 *3.85 2.66 @7.96
3 *15.02 12.91 *10.49 8.05 *8.37 5.64 *7.15 4.21 5.62 3.25 4.49 2.57 *4.05 2.47 @8.16
2 *7.98 *7.98 *12.16 7.49 *9.37 5.32 7.05 4.01 5.49 3.13 4.41 2.49 4.21 2.37 @8.23
1 *7.79 *7.79 *13.23 7.12 9.25 5.07 6.86 3.85 5.37 3.02 4.34 2.42 4.19 2.34 @8.18
0 *9.50 *9.50 13.49 6.93 9.06 4.91 6.73 3.72 5.28 2.94 4.29 2.38 4.29 2.38 @8.00
-1 *8.70 *8.70 *11.88 11.35 13.41 6.86 8.96 4.83 6.65 3.66 5.23 2.89 4.53 2.51 @7.69
-2 *11.36 *11.36 *14.82 11.44 *12.92 6.87 8.95 4.81 6.63 3.64 5.22 2.89 4.98 2.76 @7.23
-3 *14.30 *14.30 *15.04 11.6 *11.89 6.96 9.00 4.86 6.68 3.68 5.79 3.22 @6.58
-4 *16.51 *16.51 *12.79 11.85 *10.27 7.12 *8.29 4.98 *7.07 4.12 @5.68
-5 *9.50 *9.50 *7.65 7.40 *6.96 6.42 @4.37
Safety DX235LCR
1-62
Feet
A (ft) 10 15 20 25 Max. Reach
A (ft)
B (ft)
25 *11.95 *11.95 *8.50 *8.50 @19.29
20 *12.73 *12.73 *12.13 10.12 *8.14 7.66 @23.20
15 *19.97 *19.97 *15.63 *15.63 *13.54 9.68 *9.58 6.47 *8.31 6.21 @25.53
10 *31.98 27.84 *19.96 14.38 *15.50 9.06 10.77 6.19 *8.91 5.47 @26.74
5 *17.46 *17.46 *23.90 13.11 14.95 8.45 10.44 5.89 9.23 5.17 @26.98
0 *21.52 *21.52 23.29 12.41 14.46 8.02 10.19 5.66 9.45 5.24 @26.26
-5 *29.95 24.35 23.04 12.2 14.26 7.84 10.43 5.77 @24.51
-10 *32.56 24.83 *23.04 12.35 14.37 7.93 12.89 7.16 @21.47
-15 *24.18 *24.18 *17.34 12.91 *15.58 11.26 @16.39

DX235LCR Safety
1-63
Option: Boom 5.7 m, Arm 2.4 m, Shoe 800 mm

A Boom 5.7 18 8
Arm 2.4 7 11
Shoe 800 mm (32 )
B
UNIT : 1,000 kg (1,000 Ib)
: Rating Over Front
FG015901
Figure 57
Metric
A (m) 2 3 4 5 6 7 Max. Reach
A (m)
B (m)
8 *6.40 *6.40 *5.44 *5.44 @4.81
7 *6.33 *6.33 *6.20 *6.20 *5.14 4.86 @5.88
6 *6.88 *6.88 *6.46 6.38 *6.20 4.64 *5.06 3.87 @6.62

5 *9.64 *9.64 *8.02 *8.02 *7.09 6.16 *6.51 4.52 *5.80 3.44 *5.12 3.30 @7.16
4 *13.16 *13.16 *9.67 8.44 *7.99 5.87 *7.02 4.36 5.73 3.35 5.08 2.95 @7.51
3 *11.50 7.84 *9.00 5.56 7.23 4.17 5.61 3.25 4.76 2.74 @7.73
2 *12.96 7.36 9.48 5.27 7.03 4.00 5.49 3.14 4.61 2.62 @7.80
1 *13.66 7.09 9.23 5.07 6.87 3.86 5.39 3.05 4.60 2.59 @7.75
0 *8.57 *8.57 13.55 6.99 9.09 4.95 6.76 3.77 5.32 2.99 4.73 2.66 @7.56
-1 *8.95 *8.95 *12.28 11.62 *13.29 6.97 9.04 4.90 6.72 3.72 5.3 2.96 5.05 2.83 @7.23
-2 *12.63 *12.63 *15.52 11.72 *12.48 7.02 9.06 4.92 6.73 3.73 5.64 3.16 @6.74
-3 *16.60 *16.60 *13.74 11.90 *11.19 7.14 *9.13 5.00 6.82 3.81 6.76 3.78 @6.03
-4 *13.53 *13.53 *11.17 *11.17 *9.19 7.34 *7.34 5.17 *7.26 5.13 @5.03
Safety DX235LCR
1-64
Feet
A (ft) 10 15 20 25 Max. Reach
A (ft)
B (ft)
25 *13.84 *13.84 *11.66 *11.66 @17.25
20 *14.47 *14.47 *13.60 9.96 *11.15 8.70 @21.53
15 *23.85 *23.85 *17.40 15.46 *14.67 9.57 *11.43 6.91 @24.04
10 *21.63 14.11 15.54 8.99 10.76 6.19 10.52 6.05 @25.33
5 23.99 13.01 14.93 8.45 10.49 5.94 10.12 5.73 @25.57
0 *19.54 *19.54 23.37 12.5 14.54 8.11 10.43 5.85 @24.81
-5 *32.22 24.93 23.29 12.43 14.44 8.02 11.70 6.55 @22.96
-10 *29.78 25.47 *21.81 12.69 15.06 8.43 @19.67
-15 *19.96 *19.96 *15.46 15.03 @13.96

DX235LCR Safety
1-65
Safety DX235LCR
1-66
2Operating Controls
The "Operating Controls" section presented here consists of the
following groups:
1. "Component Locations" on page 2-2
2. "Operator's Area" on page 2-4
3. "Operational Controls and Panels" on page 2-6
4. "Instrument Panel" on page 2-19
5. "Multifunction Gauge and Graphic Information" on
page 2-25
6. "Mode Selector Buttons" on page 2-31
7. "Setting Main Menu" on page 2-33
8. "Heater and Air Conditioner Control Panel" on page 2-47
9. "Stereo" on page 2-52
10. "Miscellaneous Electrical Devices" on page 2-53
11. "Seat Adjustment" on page 2-55
12. "Ceiling Cover" on page 2-59
13. "Front Windows" on page 2-60
14. "Door Side Latch" on page 2-62
15. "Cabin Storage Compartments" on page 2-63
16. "Ashtray" on page 2-63
17. "Sun Visor" on page 2-64
18. "Hanger" on page 2-64
19. "Cup Holder" on page 2-64
20. "Emergency Glass Breaking Tool" on page 2-65
21. "Miscellaneous Access Covers and Doors" on page 2-66
Each group is explained with a point location drawing or photo

and a brief description of each control, switch, gauge or valve.
Indicator lights work besides the gauges on the instrument
panel. The operator should monitor machine pressure on the
instrument panel with indicator lights. These lights will only show
there is a problem.
WARNING
Warning lights. When any one or more of the warning lights
on the control console, comes "ON", immediately stop
operation and stop unit. Investigate and correct the
problem before proceeding with operation.
DX235LCR Operating Controls

2-1
COMPONENT LOCATIONS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
21
22
38
37 23
36
35
34
33 26 24
32
25
31 27
30
29
28
FG016014
Figure 1
Operating Controls DX235LCR

2-2
Reference Reference
Description Description
Number Number
1 Counterweight 20 Boom
2 Muffler 21 Arm
3 Fuel Tank 22 Bucket Cylinder
4 Fuel Tank Fill Cap 23 Guide Link
5 Engine Bonnet 24 Push Link
6 Hydraulic Oil Tank 25 Bucket
7 Engine 26 Tooth Point
8 Swing Motor 27 Side Cutter
9 Radiator and Oil Cooler 28 Idler
10 Center Joint 29 Track Adjuster
11 Swing Bearing 30 Control Valves
12 Battery 31 Track Link and Shoe
13 Air Cleaner 32 Return Filter
14 Cabin 33 Suction Filter
15 Seat 34 Track Guide
16 Boom Cylinder 35 Lower Roller
17 Work Lever (Joystick) Controls 36 Upper Roller
18 Travel Lever 37 Pumps
19 Arm Cylinder 38 Travel Motor

2-3
OPERATOR'S AREA
13
14
10
8 17
7
9
6
5
4
2
3
11
1
12
16
15
FG015902
Figure 2

2-4
Reference Reference
Number Number
Instrument Panel Seat
1 10
(See page 2-19) (See page 2-55)
Cigarette Lighter Storage Compartment
2 11
Ashtray 12 Heater and Air Conditioner Unit
3
(See page 2-63) Stereo
13
Travel Levers (See page 2-52)
4
(See page 3-16) Fuse Box
14
Right-hand Work Lever (Joystick) (See page 2-54)
5
(See page 3-25) Left-hand Work Lever (Joystick)
15
6 Switch Panel (See page 3-24)
Engine Speed Control Dial Safety Lever
7 16
Heater and Air Conditioner Storage Compartment
17
8 Control Panel (See page 2-63)
(See page 2-47)
Starter Switch
9
(See page 2-8)

2-5
OPERATIONAL CONTROLS AND
PANELS
25 24 23
17 16 18
19
21
3 2 1 20
15 13 12 11 10 9 8 7 6 14 22
FG015903
Figure 3

2-6
Reference Reference
Number Number
1 Starter Switch 14 Cigarette Lighter
2 Engine Speed Control Dial 15 Power Socket For 12v
3 Quick Coupler Switch (Optional) Travel/Swing Alarm Switch
16
4 Auxiliary Mode Switch (Optional)
5 Engine Emergency Stop Switch 17 Seat Warmer Switch (Optional)
6 Audio Control Panel 18 Horn Button
7 Travel Speed Selector Switch 19 Rotating Switch
8 Light Switch 20 Breaker/Booster Switch
Breaker/Booster/Shear Selector 21 Shear Switch
9
Switch 22 Instrument Panel
Cabin Work Light Switch 23 Safety Lever
10
(Optional) Overload Warning Switch
24
11 Warning Light Switch (Optional) (Optional)
Heater and Air Conditional 25 Fuel Heater Switch (Optional)
12
Control Panel
13 Wiper Control Panel

2-7
1. Starter Switch
O I
A three-position starter switch is used to start or stop
engine for equipment operation.
O. 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.
I. Turning switch to this position turns engine electrical
system "ON". When switch is first turned "ON" six
FG000014
indicator/warning lights across top of instrument
Figure 4
panel, will light for approximately two seconds. The
battery warning light and engine oil pressure warning
light should remain "ON" after the other four have
turned "OFF".
NOTE: Preheat Indicator Light - The operation of
the preheat cycle depends on coolant
temperature. When the engine coolant is
cold enough, the preheat indicator light will
remain "ON" until engine preheat cycle is
completed. The preheat cycle takes about
twenty seconds to complete, and the
indicator light will turn "OFF". When the
light turns "OFF", engage the starter.
. Moving switch to this position will crank engine.
When engine starts, release key and allow it to return
to "I" (ON) position. Do not operate the starter switch
for more than fifteen seconds at a time. This will help
prevent damage to starter.
WARNING
DO NOT USE STARTING FLUIDS. The preheat system
could cause the starting fluid to explode. Starting
fluids should never be used.

2-8
2. Engine Speed Control Dial
The engine speed is controlled by the dial. Rotating it
clockwise increases engine speed (rpm) and
counterclockwise decreases engine speed.
A Low idle (Lowest engine speed)
B 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
neutral position. This system is designed to Figure 5
reduce fuel consumption and noise. See "3.
Auto Idle Selector Button" on page 2-32.
3. Quick Coupler Switch (Optional)

O
Clamp releasing for dispensable attachment is controlled. I
O. In this position , the quick coupler is "LOCKED".
The attachment is secured to the arm.
I. In this position , the quick coupler is "UNLOCKED".

The attachment is released from the arm.
NOTE: To move the switch, pull up on the toggle and
then move it into "UNLOCKED" position. FG001342
Figure 6
WARNING
When the attachment is still connected to the machine,
while the switch is "I" ( ) position, do not operate the
machine or the attachment might fall to the ground. It
would cause personnel injuries.
4. Auxiliary Mode Switch

I O
When the control system is out of order, the pump system
can be controlled manually.
O. In this position, the manual pump control is "OFF".
I. In this position, the manual pump control is "ON".
CAUTION
FG001343
AVOID INJURY Figure 7
Be sure to turn pump control to "O" (OFF) position,
after the control system is operating properly.

2-9
5. Engine Emergency Stop Switch
If the engine does not stop when using the starter switch, it
O I
can be stopped by moving the engine emergency stop
switch to "I" (EMERGENCY STOP) position.
O. In this position, the engine emergency stop system is
"OFF".
I. In this position, "EMERGENCY STOP" is selected.
The engine will stop.
NOTE: When released, the switch will return to its FG001344
original position "O" (OFF) position. Figure 8
6. Audio Control Panel

The audio system can be remotely controlled using this
panel. SCAN
PWR
FG000018
Figure 9
Each time this power button is pressed, the audio system

is turned either "ON" or "OFF".
If the audio system turns "ON", an indicator light above the
button turns "ON".
PWR
FG000019
Figure 10
Press the up button, to "INCREASE" volume.
FG000020
Figure 11

2-10
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
pressed to stop the scan.
SCAN
FG000022
Figure 13
7. Travel Speed Selector Switch

O
I
WARNING II
Do not operate the travel speed selector switch when
unit is in motion. Temporary loss of control could
result.
FG000023
This switch activates the automatic speed range for travel. Figure 14
O. In this position, "LOW" travel speed is selected.
I. In this position, "HIGH" travel speed is selected.
II. In this position, "AUTOMATIC" travel speed is
selected. The travel speed automatically changes
between "LOW" or "HIGH" range, depending on
engine speed and travel motor loads.

2-11
8. Light Switch
This switch is used to turn "ON" the lights. O
O. In this position, all lights are "OFF".
I
II
I. In this position, all illumination lights of the instrument
panel and the control switches are turned "ON".
II. In this position, all illumination lights and work lights
are turned "ON".
FG000024
CAUTION Figure 15
AVOID INJURY
Do not leave instrument panel or work lights "ON"
when the engine is not running. Leaving lights "ON"
with the engine stopped will discharge batteries.
9. Breaker/Boost/Shear Selector Switch

This switch is used to either select the breaker, power I
boost, or shear. O
O. In this position, a hydraulic pressure rise will be II P
RU
activated when pressing the button on the right-hand WE
PO
work lever (joystick).
I. In this position, shear is activated.
II. In this position, breaker is activated.
FG000025
Figure 16
CAUTION
AVOID INJURY
Before using any attachment in a work application, be
sure to check its functional control. Make sure that
desired movement or action is being activated by the
control. e.g. opening/closing, CW/CCW, crowd/dump,
etc.

2-12
10. Cabin Work Light Switch (Optional)
This switch is used to control the cabin work lights, if unit is O
equipped with them. I
O. In this position, all cabin work lights are turned "OFF". II
I. In this position, the front cabin work lights on the front
top of cabin will turn "ON".
II. In this position, the front cabin work lights on the front
top of cabin and rear cabin work lights on rear top of
cabin will turn "ON". FG000026
Figure 17
11. Warning Light Switch (Optional)

If unit is equipped with a warning light, push this switch to O
activate it.
O. In this position, the warning light is turned "OFF". I
I. In this position, the warning light turns "ON" and will
start flashing.
FG000027
Figure 18
12. Heater and Air Conditioner Control

Panel
This panel is used to control air conditioner and heater in
operator's cabin. Refer to "Heater and Air Conditioner
Control Panel" on page 2-47 for more details.
FG014507
Figure 19

2-13
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.
FG000308
Figure 20
Constant Speed Button

Pressing the button turns "ON" the windshield wiper. An
indicator light above the button will turn "ON" indicating
that wiper is "ON". The wiper will run at a constant speed.
Pressing the button again, turns "OFF" the windshield
wiper.
FG000241
Figure 21
Intermittent Speed Button

Pressing button once (first time):
Windshield wiper runs approximately on a three second
intermittent cycle. The left side indicator light will turn "ON".
Pressing button again (second time):
Windshield wiper runs approximately on a six second
intermittent cycle. The right side indicator light will turn
"ON".
Pressing button again (third time):
Turns "OFF" the windshield wiper. Both indicator lights will
be turned "OFF". FG000242
Figure 22
Windshield Washer Button

Pressing the washer button will spray windshield washer
fluid onto the windshield. Use only the proper windshield
washer fluid in the system.
NOTE: Do not operate the windshield washer without
any fluid. If operate without any fluid, the
washer motor may be damaged. Check level in
washer tank, and add fluid as required.
NOTE: Using soapy water or synthetic detergent
instead of window cleaning fluid, can damage FG000243
the wiper blade or painted surfaces. Use Figure 23
standard window cleaning fluid: SSK703.

2-14
14. Cigarette Lighter
R
PW
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.
NOTE: This cigarette lighter is for 24V only. Never
connect a 12V electrical device to the lighter.
FG000030
Figure 24
15. Power Socket for 12 Volt

This is a power socket for only 12V DC devices.
This socket can be used for charging a cellular phone or
powering a small 12V DC electrical device. 12 V
Open the cap when using it.
NOTE: This socket is designed for small electrical 7A
capacity devices. Do not use this socket for
large electrical capacity devices. Thus, damage
can be avoided. FG017015
Figure 25
16. Travel/Swing Alarm Switch (Optional)

If unit is equipped with a travel/swing alarm buzzer, push O
this switch to active it, whenever swinging or traveling. I
O. In this position, the travel/swing alarm system is II
turned "OFF".
I. In this position, the travel alarm will only sound, when
the machine is moving.
II. In this position, the travel/swing alarm will sound
while swinging and traveling, if equipped with a swing FG000031
alarm device. Figure 26
NOTE: If machine is only equipped with a travel
alarm device, the alarm will not sound
when swinging although the switch is in
the "II" position.

2-15
17. Seat Warmer Switch (Optional)
If the seat is equipped with the optional seat warmer, push O
this switch to activate it.
When the seat is warmed, the warmer is automatically I
turned "OFF".
O. In this position, the seat warmer is turned "OFF".
I. In this position, the seat warmer is turned "ON".
NOTE: The starter switch must be "ON" with the engine
FG000034
running, for the heater to operate.
Figure 27
18. Horn Button (Left-hand Work Lever)

Press the lower button on the top of the left-hand work
lever (joystick) to sound horn.
NOTE: The starter switch must be "ON".
FG015904
Figure 28
19. Rotating Buttons 2

For a machine equipped with an attachment that rotates, 1
press the upper two buttons on the top of the left-hand
work lever (joystick) to rotate the attachment clockwise or
counterclockwise. Left button is for counterclockwise and
the right one is for clockwise.
CAUTION
FG015905
AVOID INJURY Figure 29
etc.

2-16
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" on page 2-12.
FG000036
Figure 30
21. Shear Buttons

For a machine equipped with shear, press the two upper
buttons on the top of the right-hand work lever (joystick) to
open or close the shear. Left button is for closing (crowd),
right button is for opening (Dump).
NOTE: These buttons work with the breaker/boost/
shear selector switch. See "9. Breaker/Boost/
Shear Selector Switch" on page 2-12.
FG000383
CAUTION Figure 31
AVOID INJURY
etc.
22. Instrument Panel

See "Instrument Panel" on page 2-19.
E F
C H C H
1 2 3 4 5
6 7 8 9 0
FG013662
Figure 32

2-17
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 O
this switch to activate it.
O. In this position, the overload warning device is turned I
"OFF".
I. In this position, when a load is lifted that reaches the
machine safe lifting limit, a warning light on the
instrument panel will turn "ON" and a warning buzzer
will sound.
FG000032
Figure 34
WARNING
To prevent injury, do not exceed the rated load
capacity of the machine. If the machine is not on level
ground, load capacities will vary. There may be local
government regulations about the use of excavators
for lifting objects.
Please observe these regulations.
25. Fuel Heater Switch (Optional)

This switch is used to activate the fuel heater system. O
When the switch is activated, the fuel is warmed,
depending upon the temperature of the fuel. I
NOTE: If the fuel temperature is above 5°C (41°F),
heating system is not activated.
O. In this position, the fuel heater system is turned
"OFF".
I. In this position, the fuel heater system is turned "ON". FG000033
Figure 35
NOTE: The starter switch must be "ON".

2-18
INSTRUMENT PANEL
7 8 9 10 11 12 5
6 1
1 CHECK
E
< CONNECTOR AND TERMINAL NO.>
F 4
16
C H C H 18
AMP 040 28P
14 20 6 5 4 3 2 1 8 7 6 5 4 3 2 1
12 11 10 9 8 7 16 15 14 13 12 11 10 9
22
13 (CN7) (CN6)
1 2 3 4 5
23
6 7 8 9 0
15
17 19 21 FG013521
Figure 36
Reference Reference
Number Number
1 Fuel Gauge Power Mode Selector Button
14
Engine Coolant Temperature (See page 2-31)
2
Gauge Economy Mode Selector Button
15
3 Hydraulic Oil Temperature Gauge (See page 2-31)
Multifunction Gauge and Graphic Auto Idle Selector Button
4 16
Information Area (See page 2-25) (See page 2-32)
5 Digital Clock Flow Control Button
17
(See page 2-32)
6 Hour Meter
Up Arrow Button
7 Charge Warning 18
(See page 2-33)
8 Engine Oil Pressure Warning
Down Arrow Button
Engine Coolant Temperature 19
9 (See page 2-34)
Warning
Display Selector Button
10 Engine Check Warning 20
(See page 2-34)
11 Preheat Indicator 21 Selection Button (See page 2-34)
12 Work Light Indicator 22 Home Selector Button
13 Warning Light 23 Camera Selector Button

2-19
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).
Password Activated
If a password has already been set and the system has been
"LOCKED", the password display will appear on the screen once
the functional check has been completed. Enter the password
into the text area and then engage the starter.
NOTE: Refer to "Set Password (Lock and Unlock)" on
page 2-40, for further details.
CAUTION
AVOID INJURY
If the password does not match the stored password, the
engine will not start.
1. Fuel Gauge
Shows remaining fuel quantity in tank.
BLUE ZONE ( ) - Indicates a normal fuel quantity.
RED ZONE ( ) - Indicates that the fuel level is low.

If the gauge pointer moves into the red zone, the fuel level
symbol will turn "ON", and be display in the screen. Stop E F
operation and immediately and add fuel.
NOTE: See "Abnormal State Warning Symbols" on FG014483
page 2-27, for location of this warning symbol Figure 37
and others.
Check the fuel level on firm and level ground.

2-20
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

C H
normal operating range.
RED ZONE ( ) - Indicates temperature is too high. FG013672

Figure 38
During operation, the pointer must be in the blue zone.
If the gauge pointer moves into the red zone, the engine
coolant temperature warning light will turn "ON", a warning
buzzer will sound, and the engine speed will be
automatically reduced. Allow the engine to run at low idle
speed until temperature gauge registers in the blue zone
again. When the blue zone is reached, allow the engine to
idle for an additional three - five minutes before shutting
down the engine. If not allowed to idle, heat surge may
develop which will damage the engine. Allowing the engine
to idle will dissipate heat. Check the coolant level, look for
a loose fan belt, inspect for debris around radiator, and so
on.
When the temperature reaches the normal range, the
engine speed will automatically recover.
3. Hydraulic Oil Temperature Gauge

The colored bands indicate the temperature of the
hydraulic oil
WHITE ZONE ( ) - Indicates temperature is lower than

the normal operating temperature.
BLUE ZONE ( ) - Indicates temperature is within the C H

normal operating range.
RED ZONE ( ) - Indicates temperature is too high. FG013673

Figure 39
During operation, the pointer must be in the blue zone.
If the gauge pointer moves into the red zone, the hydraulic
oil temperature symbol will turn "ON", and be display in the
screen. Allow the engine to run at low idle speed until
temperature gauge registers in the blue zone again.
NOTE: See "Abnormal State Warning Symbols" on
page 2-27, for location of this warning symbol
and others.

2-21
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.
E F
C H C H
FG013591
Figure 40
5. Digital Clock
A digital clock, shows the current time. The displayed
contents are as follows.
Display Description
MM Month MM/DD [W] HH:mm
DD Date
W Day
HH Hour
FG000044
mm Minute
Figure 41
A (P) AM (PM)
Refer to "Setting Main Menu" on page 2-33 for time setting.
6. Hour Meter
The hour meter is used to indicate the total number of
running hours on the engine. The meter will flash every
four seconds when the engine is running to indicate that it
is functioning properly.
HAOA601L
Figure 42
7. Charge Warning
This symbol indicates when the engine starter switch is
turned "ON", and should go "OFF" after the engine starts. If
it does not turn "OFF", shut the engine down immediately
and determine the cause of the problem.
Figure 43 HAOA610L

2-22
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. If you continue to
work when this light is "ON", it will result in serious engine
damage.
HAOA620L
CAUTION Figure 44
AVOID INJURY
If you continue to work when this light is "ON", it will
result in serious engine damage.
9. Engine Coolant Temperature Warning

If engine coolant overheats, this symbol appears on the
screen an alarm will sound, and the engine speed will be
automatically reduced, until coolant temperature drops. Do
not turn engine "OFF" because this will cause coolant
temperature to rise and can cause engine to siege
because of heat surge.
NOTE: Check the engine coolant temperature gauge. If
the gauge pointer moves into the red zone, the
engine coolant temperature warning light will
turn "ON", a warning buzzer will sound, and the HAOD350L
engine speed will be automatically reduced. Figure 45
Allow the engine to run at low idle speed until
temperature gauge registers in the blue zone
again. When the blue zone is reached, allow the
engine to idle for an additional three - five
minutes before shutting down the engine. If not
allowed to idle, heat surge may develop which
will damage the engine. Allowing the engine to
idle will dissipate heat. Check the coolant level,
look for a loose fan belt, inspect for debris
around radiator, and so on.
When the temperature reaches the normal
range, the engine speed will automatically recover.

2-23
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.
When this indicator symbol turns "OFF", it means that
engine preheat cycle has been completed.
HAAE2000
Figure 47
12. Work Light Indicator

The indicator symbol indicates that work lights are turned
"ON".
HB4O2003
Figure 48
13. Warning Light

This warning light appears when the machine or engine
need to be check.
NOTE: If warning light appears, Stop the machine and
repair the cause of the fault
If camera mode is being used, Move to the main
screen and check the fault
FG017012
Figure 49

2-24
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". Each time the
display selector button (19, Figure 36) is pressed, the digital E F
readout changes in the following sequence; Engine speed (rpm) C H C H
-> Battery voltage (VOLT) -> Front pump pressure (BAR) ->
Rear pump pressure (BAR).
FG013591
NOTE: See Figure 53 thru Figure 56. Figure 50
A digital clock is located at the top of the display.
By using a combination of the mode selector buttons,
information for filters and oils can also be displayed.
The display can also be set for the desired language.
Refer to the "Setting Main Menu" on page 2-33 for the language
selection and information display sequences.
Communication Indicator
Indicates the condition of communication between main
controller and instrument panel.
1. Normal Condition:
The symbol will sequentially move like lightening.
NOTE: See Figure 53 thru Figure 56.
2. Abnormal Condition:
If the symbol is not displayed, it means there is a FG000047
communication error. Figure 51
NOTE: See Figure 52.

2-25
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. e.g. power mode, work
mode and auto idle are stored during failure.
NOTE: When starter switch is turned to "I" (ON) position FG000048
during a state of communication error failure, the Figure 52
EPOS controller will default to the following modes.
Power mode: Standard mode
Working mode: Digging mode
Auto idle: "ON" (Selection state)
Engine Speed
The engine speed is numerically displayed.
E/G SPEED 1700 RPM
FG000049
Figure 53
Battery Voltage
The battery voltage is numerically displayed. With the engine
running, the reading must be between 26V - 30V.
When the starter is engaged or the preheat system is being
used, the voltage can temporarily drop below 24V, but this is a BATTERY 28.0 VOLT
normal condition.
FG000050
Figure 54

2-26
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.
It displays the reading in BARs.
FRONT PUMP 320 BAR
FG000051
Figure 55
Rear Hydraulic Pump Pressure

The rear pump pressure is numerically displayed.
NOTE: This pump is the farthest from engine flywheel
housing or is the lower one of hydraulic pump.
It displays the reading in BARs.
REAR PUMP 313 BAR
FG000052
Figure 56
Abnormal State Warning Symbols 6 5 4 3 2 1

1. Hydraulic Oil Overheating Warning
2. Fuel Shortage Warning
3. Return Filter Clogged Warning
4. Air Cleaner Clogged Warning
5. Overload Warning (Optional)
6. Water in fuel Warning
DS1801626
Figure 57

2-27
Examples of Warning Display
FG013703 FG013704 FG013705
<2 kinds of warning display> <4 kinds of warning display> <7 kinds of warning display>
Figure 58
1. Hydraulic Oil Overheat Warning

If the hydraulic oil temperature is too high, this symbol
appears on the screen.
FG000056
Figure 59
2. Fuel Shortage Warning

If the fuel quantity is too low, this symbol appears on the
screen.
If this light turns "ON", add fuel as soon as possible.
FG000057
Figure 60

2-28
3. 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
4. Air Cleaner Clogged Warning

This symbol indicates when the air cleaner is clogged.
If this symbol is displayed, immediately stop operation and
replace or clean the air filter.
After the air filter has been serviced, restart machine
operation to remove warning symbol.
FG000053
Figure 62
5. Overload Warning (Optional)

If the overload warning switch is turned "ON", and this
symbol appears on the screen and the warning buzzer
sounds, that indicates that overloaded condition is
occurring. Immediately reduce the load.
WARNING
FG000253
If this warning appears on the screen and a warning Figure 63
buzzer sound, reduce the load immediately.
If you continue to work, the machine can be turned
over or damage to hydraulic components and
structural parts could occur.

2-29
6. 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

2-30
MODE SELECTOR BUTTONS
1 3
1. Power Mode Selector Button
2. Economy Mode Selector Button
1 2 3 4 5
3. Auto Idle Selector Button
4. Flow Control Button
6 7 8 9 0
2 4
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" or "OFF".
When the power mode button is pushed to "ON" position,
an indicator light above it turns "ON".
1
When the power mode button is pushed again, it is turned
"OFF" and the power mode is deactivated and returns to
the standard operating mode.
FG013709
When turning the engine starter switch to "I" (ON) position, Figure 66
the power mode is automatically defaulted to "Standard
Mode".
NOTE: For further details, see "Mode Selection" on
page 3-21.
2. Economy Mode Selector Button

Economy mode is used for light loading work, when this
mode selected it will reduce noise and fuel consumption
with standard mode.
When the economy mode button is pushed to "ON"
position, a symbol appears on the screen.
6
NOTE: When the economy mode button is pushed
again, it is turned OFF and the economy mode
is deactivated and returns to the standard
FG013710
operating mode.
Figure 67

2-31
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.
2
When the auto idle selector button is pushed to "ON"
position, an indicator light above it turns "ON".
When the auto idle selector button is pushed again, it is
FG013711
turned "OFF" and the engine speed will return to the
Figure 68
setting of the engine speed dial and will remain at this
speed despite control lever position, until engine speed dial
is moved.
4. Flow Control Button

When the button is pushed, you can control the hydraulic
oil flow rate.
The flow control button is used to set the flow rate of pump
to match the installed tool/attachment for optimal
performance, without damaging it.
NOTE: For further details, see "Flow Control" on 7
page 2-42.
FG013896
Figure 69

2-32
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.
E F
C H C H
FG013591
Figure 70
1 3 5
1 2 3 4 5
6 7 8 9 0
2 4
FG013712
Figure 71
1. Up Arrow Button
Up arrow button ( ), is used to move a menu item "Up" or
to "Left".
FG000068
Figure 72

2-33
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. Each time the display
selector button is pressed, the digital readout changes.
NOTE: When setting the main menu, this button is used
as the menu/exit button (ESC). To access the
4
menus the button must be pressed and held for
three seconds.
NOTE: When this button is used for menu/exit button, it FG000070
is used to access to main menu or return to a Figure 74
previous screen from each submenu.
4. Selection Button
Selection button ( ), is used to set a menu or clear the
operating hour of filter/oil.
FG013898
Figure 75
5. Home Button
Home button (HOME), is used to access to the default
screen from each submenu.
FG013713
Figure 76

2-34
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.
MAIN MENU
L 1. Language
l
2. Set Clock
l
3. Filter / Oil Info
E F
4. Adjust Display
C H C H 5. Set Password
: UP : DOWN : SELECT
FG015019
Figure 77
ESC Button
The screen will return from the main menu to the normal display
screen, by again pressing the "ESC" ( ) button.
NOTE: If more than twenty seconds are spent in any menu,
without changing the screen, it will return to the
normal display screen.
E F
C H C H
FG013591
Figure 78

2-35
Main Menu
MAIN MENU
The menu selection can be changed by pressing the "UP" ( )
L 1. Language
or "DOWN" ( ) buttons. The selected menu item will be l
2. Set Clock
l
highlighted, and a cursor will appear by the menu item.
When the selected menu item is highlighted, press the
"SELECT" ( ) button to enter the next submenu.
4. Adjust Display
5. Set Password
1. "Language" on page 2-36.
2. "Set Clock" on page 2-36.
FG013563
3. "Filter/Oil Info" on page 2-37. Figure 79
4. "Adjust Display" on page 2-39.
5. "Set Password (Lock and Unlock)" on page 2-40.
Language
L Languag
When the cursor is on "Language", press the "SELECT" ( )
button. The language submenu will appear. 1. Korean
The desired language can be selected by using the "UP" ( ) or 2. English

"DOWN"( ) buttons.
The display can be set for the desired language.
Press the "SELECT" ( ) button to set the selected language. : UP : DOWN : SET
NOTE: If more than twenty seconds are spent in the menu, FG013564
without changing the screen, it will return to the Figure 80
Set Clock
MAIN MENU
When the cursor is on "Set Clock", press the "SELECT" ( )
button. The set clock submenu will appear.
L 1. Language
l
2. Set Clock
l
NOTE: If more than twenty seconds are spent in the menu,

normal display screen. 4. Adjust Display
5. Set Password
FG013565
Figure 81

2-36
Setting Method
1. Move the cursor to desired number by using the "SELECT"
SET CLOCK
( ) button. When selected the number will flash.
2. Set the time by using the "UP" ( ) or "DOWN"( ) 02:30:30

2003 11/04
buttons.
• "+" ( ), "-" ( ): Increase or decrease number.

• "MOVE" ( ): Confirm and move the cursor to next
number. : UP : DOWN : SELECT
FG013566
• "ESC" ( ): Exit to the main menu. Figure 82
'00' Minute Setting

1. Simultaneously press the "SELECT" ( ) button and "UP"
SET CLOCK
( ) button.
2. If the displayed time is 30 minutes or less, the clock will 02:30:30
2003 11/04
display the preceding hour.
3. If the displayed time is more than 30 minutes, the clock will
display the succeeding hour.
4. When the preceding hour is more than 23, the day will be : UP : DOWN : SELECT
increased. FG013566
Figure 83
Filter/Oil Info
MAIN MENU
When the cursor is on "Filter/Oil Info", press the "SELECT" ( )
button. The filter/oil information submenu will appear.
L 1. Language
l
2. Set Clock
l

4. Adjust Display
5. Set Password
FG013567
Figure 84
Each symbol can be selected by pressing the "UP" ( ) or

"DOWN" ( ) buttons. At the bottom of the screen the operating Filter/Oil Information
hour (Hrs) of each filter and/or oil is displayed. R
1. Fuel Filter
Hrs : 0045Hrs 42m
FG013568
Figure 85

2-37
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

After changing a filter or oil, reset the operating hour to zero Filter/Oil Information
(Hrs: 0000). The next replacement period can than be easily R
checked. The operating hours are only accumulated while the
engine is running. P
On the filter/oil information screen, press the "SELECT" ( )
button and then the reset screen will be displayed. RESET?
YES : NO : ESC
On the reset screen, the operating hour can be changed to zero
hour (Hrs: 0000) by pressing the "SELECT" ( ). : UP : DOWN : SELECT
FG013716
If the "SELECT" ( ) button is pressed, the reset will be Figure 87
completed. and the screen will be returned to the previous
menu.
If the "ESC" ( ) button is pressed, the screen will be returned

to the previous menu without being reset.
NOTE: If more than twenty seconds are spent in the menu,
The screen is returned to the main menu by pressing the "ESC"
( ) button.

2-38
Adjust Display
MAIN MENU
When the cursor is on "Adjust Display", press the "SELECT"
( ) button. The adjust display submenu will appear.
L 1. Language
l
2. Set Clock
l
4. Adjust Display
5. Set Password
FG013569
Figure 88
When the cursor is on "Adjust Display", press the "SELECT"

( ) button. The adjust display submenu will appear.
1. Adjust Display
2. Adjust Display (Camera)
FG013835
Figure 89
1. Move the cursor to desired characteristic about display by

using the "SELECT" ( ) button. Adjust Display
2. The desired brightness, contrast, backlight adjustment can Brightness l llllllllllllllllllllllll l 50%
l
be selected by using "UP" ( ) or "DOWN" ( ) buttons.
Contrast lllllllllllllllllllllllll l 50%
l
l
NOTE: When the equipment shipped and it is day
mode ( ), the default brightness and contrast
Back Light llllllllllllllllllllllll l 50%
l
l
is set to 50%, the default backlight is set to
90%.
When it is night mode ( ), the default FG013570
brightness is set to 50%, the default contrast is Figure 90
set to 30%, the default backlight is set to 10%.
Default value of camera display is 50%
(brightness), 50% (contrast), 90% (backlight).
The screen is returned to the main menu by pressing the "ESC"
( ) button. The display is then saved.

2-39
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.
Write your password down and keep it in a safe location.
Password numbers can only use numbers between 1 and 8. The
small number to the lower left of each button on the instrument
panel, indicates the number that will be entered when that button
is pressed. Numbers "0" and "9" are invalid choices.
Example: E F
C H C H
2785 is acceptable.
9024 is not acceptable.
1 2 3 4 5
6 7 8 9 0
FG013662
Figure 91
When the cursor is on "Set Password" press the "SELECT"

( ) button. The set password submenu will appear. MAIN MENU
NOTE: The screen can be returned to the main menu by L 1. Language
l
2. Set Clock
l
pressing the "ESC"( ) button (3, Figure 71).
4. Adjust Display
5. Set Password
FG013571
Figure 92
Password inquiry menu will be displayed.

NOTE: The initial password is "1111".
The password can be changed within ten minutes while the
ENTER
starter switch is in "I" (ON) position.
PASSWORD
After changing password, be sure to use the changed password.
CAUTION
AVOID INJURY FG013717
Figure 93
Failure to enter correct password three times, will return
normal display screen, and another attempt will not be
possible for ten minutes.

2-40
A three item menu will be displayed. The items are "LOCK",
"UNLOCK", and "CHANGE PASSWORD". An item can be
selected by using the "UP" ( ) or "DOWN" ( ) buttons, and
then selected by pressing the "SELECT" ( ) button.
Press "ESC" ( ) button (3,Figure 71) for 1 more second, it

returns to main menu.
According to the selection of adoption (lock) or nonadoption
(unlock), the password function will be in working or nonworking. Set Password
When you want to change a password, follow below procedure.
Lock
1. Move the cursor to "Change Password".
2. Input desired 4 digits password using selector buttons (at Unlock
the first column). Input the same password one more time
(at the second column)
Change Password
3. Select adoption (lock) or nonadoption (unlock) at set
password menu.
FG013718
NOTE: Keep in mind never to forget password. Figure 94
NOTE: Please contact a DOOSAN distributor, if you
forget your password.

2-41
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.
E F
C H C H
FG013591
Figure 95
When the flow control button (Figure 69 and Figure 96) is

pressed at the normal display screen (Figure 95), the flow
control screen (Figure 98) will be displayed.
FG013896
Figure 96
Select a tool by using the breaker/boost/shear selector switch.

The symbol in the upper left corner of the display screen will
change according to the position that the selector switch is in. I
Compare the symbols shown in (Figure 98 and Figure 99). O
II P
RU
WE
PO
FG000025
Figure 97

2-42
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)

0 48
: APPLY ESC: CANCEL
1 57
FG014885
2 66
Figure 98 Breaker
3 69
4 78.5
5 90
6 96.5
7 106.5
8 108
9 111
10 111
Pump flow setting is at rated engine speed, for only the output of
one pump. FLOW CONTROL
Pump displacement will vary according to changes in engine
rpm.
: APPLY ESC: CANCEL

FG014886
Figure 99 Shear
Escape
FLOW CONTROL
A. Press flow control button ( , Figure 96) to return to
normal display screen and save the flow rate setting.
B. If there is no adjustment for twenty seconds, the flow
control screen will return to the normal display screen.
: APPLY ESC: CANCEL

FG014885
Figure 100

2-43
OPERATION SELECTION
DISPLAY
In the monitor you can see the application that is currently
selected.
Power Mode Selection
PWR
FG013720
Figure 101
Standard Mode Selection
STD
FG013721
Figure 102
Economy Mode Selection
ECO
FG013722
Figure 103

2-44
Auto Idle Selection
PWR
AUTO
FG013723
Figure 104
Power Boost Selection
PWR
FG013724
Figure 105
Breaker Selection
PWR
FG013725
Figure 106
Shear Selection
PWR
FG013726
Figure 107

2-45
Quick Coupler Operation Selection
(Optional)
PWR
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. 1 2 3 4 5
When the camera mode button is pushed again, it is turned

"OFF" and the camera mode is deactivated and return to the 6 7 8 9 0
default screen. 1
FG013836
Figure 109

2-46
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.

2-47
Control Panel
1 2 3 4
LO MID HI COOL WARM
5 6 FG014376
Figure 111
Reference Reference
Number Number
1 Off Button 4 Air Inlet Selector Button
2 Air Conditioner Control Button 5 Fan Speed Selector Button
3 Air Outlet Selector Button 6 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".
1. Off Button
This button is used to stop the fan and air conditioner.
OFF
FG000089
Figure 112

2-48
2. Air Conditioner Button
This button activate or deactivate air conditioner.
When the air conditioner is turned on, the LED is lightened.
A/C
FG000105
Figure 113
3. Air Outlet Selector Button

This button is used to select which combination of air
outlets be used.
MODE
FG000096
Figure 114
A. Used to direct air flow to upper portion of operator's

cabin from both the front and rear. It will also deliver
air to the lower portion of operator's cabin from under
the operator's seat.
FG015908
Figure 115
B. Used to direct air flow to lower portion of operator's

cabin and feet.
This mode is mainly used for heating.
FG015909
Figure 116

2-49
C. Used to direct air flow to the front window and to
operator's feet.
FG015910
Figure 117
4. 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. The select
mode is displayed on the LCD.
FG000290
Figure 118
FG000291
Figure 119
5. Fan Speed Selector Buttons

These buttons are used to control the speed of the blower
fan by the stages of low, middle and high.
LO MID HI
FG014377
Figure 120

2-50
6. 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.
Additional Operating Instructions

A proper indoor temperature in summer is 5 - 6°C (10 - 12°F)
less than the outdoor temperature.
Operate the air conditioner for twenty - thirty minutes a week to
circulate the refrigerant in the system.
NOTE: The blower button must be on "Three Bars".
If operating the air conditioner or heater for a long time, operate
the air inlet selector button, and when smoking, vent the air to
the outside to prevent irritation to eyes.

2-51
STEREO
Before operating the stereo or CD player, read operation manual
enclosed with stereo.
Stereo
AM RDS
7
PUSH AST
FM VOLUME TUNE SOUND
8 MP3 ST RDS REG TA TP PTY AF DIR INT RPT RDM EQ 5
USB
USB
9
10 DISP
1 INT 2 RPT 3 RDM 4 DIR 5 DN 6 UP 4
1 3
2 FG017016
Figure 122
Reference Reference
Number Number
1 Power/Volume Control 6 LCD
2 Preset Station 7 AM Selection
3 Tuning Up/Down 8 FM Selection
4 USB Loading Port 9 USB Selection
5 Sound Mode Selector 10 Display Mode Control
CD Player (Optional)
CD
TUNE
AM/FM VOLUME TRACK SOUND
MP3 ST RDS REG TA TP PTY AF DIR INT RPT RDM EQ
USB
USB
DISP
1 INT 2 RPT 3 RDM 5 DN 6 UP
4 DIR
RDS
FG017017
Figure 123

2-52
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

When the safety lever is put into "LOCK" position, the switch
deactivates the work and travel levers. With the work and travel
levers deactivated, no digging/operational work can be done.
Unlock
Lock EX1300566
Figure 125
Circuit Breaker
A main circuit breaker is in the battery box. It will automatically
cut off in case of an electrical short circuit or overload. This will
prevent the electrical wiring and components from being burned
or damaged.
If the circuit breaker is cut off, check all related circuits, this
means something is wrong in the electric circuit.
After maintenance, press the red button for normal operation of
circuit breaker.
HAAE2110
Figure 126

2-53
Fusible Link
A fusible link is in the battery box.
A
If the engine does not crank, first check that the starter switch is
turned "ON" and that no power is available (No indicator lights
will light.). Check that "A" portion (Figure 127) of the fusible link
is not broken or burned through. Replace the fusible link if
damage and investigate cause.
WARNING Figure 127

HAAE2120

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. The fuses prevent electrical devices from overloading
or shorting.
A decal attached inside the fuse box access cover indicates the
function and amperage of each fuse.
NOTE: For a further explanation see "Fuse Boxes" on
page 2-54.
Spare fuses are mounted on the inside of fuse box access FG014508
cover. Figure 128
Change a fuse if the element separates. If the element of a new
fuse separates, check the circuit and repair the circuit.
CAUTION
AVOID INJURY
Always replace fuses with the same type and capacity fuse
that was removed. Otherwise, electrical damage could
result.

2-54
SEAT ADJUSTMENT
WARNING
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.
1. Forward/Backward Adjustment
Holding lever (1, Figure 129), raise it up, move the seat to
the desired position. Release lever to lock the seat in the
selected position. Adjustment range is 200 mm (7.9 in).
4 2
1
3 FG000183
Figure 129
2. Seat Tilt and Height Adjustment
Forward Tilt
Push lever (2, Figure 129) down to adjust the angle of the
front of the seat. There are four positions that it can be set
at.
Rear Tilt
Pull lever (2, Figure 129) up to adjust the angle of the rear
of the seat. There are four positions that it can be set at.
Seat Height
It is possible to move the seat up or down by combining
adjustments forward and rear tilt. Adjust the seat according
to operator's size and work conditions. Height adjustment
is 60 mm (2.4 in).

2-55
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. Reclining Position Adjustment

Pulling up the right lever (4,Figure 129) allows the seat
backrest to be moved forward or backward.
Sit with your back against the seat back when adjusting it.
If your back is not touching the seat back, the seat back
may suddenly move forward.
5. Armrest Angle Adjustment

The angle of each armrest can be adjusted by turning a 7
dial (5, Figure 130) on bottom of armrest. When adjusting
the angle, manually raise the armrest before turning the 9
dial.
5
8 6
6. Lumbar Support Adjustment
A lumbar support is located in the seat back.
Turn the dial (6, Figure 130) counterclockwise to increase
the force of the lumbar support FG000778
Figure 130
7. Headrest
The headrest (7, Figure 130) can be adjusted forward/
backward and up/down. Move it by holding both sides.

2-56
8. Seat Belt
WARNING
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. Never fasten a seat belt across the
abdomen.
Under no circumstances should the operator be
standing in the cabin when operating the excavator.
Do not adjust the seat position while the vehicle is
moving because a loss of control can result. Stop the
machine, apply the parking brake, and then adjust the
seat.
Always, check the condition of seat belt and belt
bracket before fastening it. Do not use it with twists in
it. Replace belt or bracket if damaged or worn.
Seat Belt Locking and Unlocking

Insert belt end (1, Figure 131) into the buckle (2). Pull the
belt to check that belt end is locked into buckle.
Adjust belt length so that it comfortably tight against the
operator's pelvic region (hipbone).
HAOB140L
Figure 131
Press the button (3, Figure 132) in the center of buckle (2)
and pull out belt (1) to unlock.
HAOB150L
Figure 132

2-57
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.
Holding lever (10, Figure 133), raise it up, set the seat to
desired position. Release lever to lock the seat in the
selected position. 10
FG016058
Figure 133
11. Air Suspension Seat (Optional)

11
The operator seat is also available with air suspension for
even better comfort. The switch (11, Figure 134) in the
middle of the seat can be used to adjust the air cushion. If
the switch is pressed, the seat become harder, and pulling
it out makes the seat softer, when the air is bleed out.
FG016059
Figure 134
12. Heating the Operator's Seat (Optional)

The air suspension seat can be heated. The switch on the O
left control stand is used to warm the seat. When heating is
not needed or seat is warmed, turn the switch to "OFF" I
position.
FG000034
Figure 135

2-58
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. Unlock
Lock EX1300566
Figure 136
Opening the Ceiling Cover

1. Lower bucket or work tool to ground.
2. Move safety lever (Figure 136) to "LOCK" position.
3. Pull lock (1, Figure 137) in front center of ceiling cover and
push it up with handle.
Closing the Ceiling Cover

2. Move safety lever (Figure 136) to "LOCK" position.
3. Pull down cover with the handle (Figure 137) so lock (1)
can be locked in the bracket in the ceiling frame.
1
FG014390
Figure 137

2-59
FRONT WINDOWS
WARNING
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.
Opening the Window
WARNING 2
AVOID DEATH OR SERIOUS INJURY 1

When stowing front window in cabin roof, make sure both
release levers (1, Figure 139) are latched.
1. Lower bucket or work tool to ground. FG014391

2. Move safety lever (Figure 138) to "LOCK" position. Figure 139
3. Set engine speed control dial to "LOW IDLE". Allow engine
to idle for three - five minutes.
4. Stop engine by turning key to "O" (OFF) position.
5. Hold window handles (1, Figure 139), then pull lock levers
(2) to release lock. The top of front window will come out.
6. Pull window up, and push it against lock pin at rear of
cabin. Make sure that it is securely latched.
7. Check that lock levers are securely latched in lock position.
NOTE: When front upper window is open, never extend
your head or body through the window frame.
NOTE: If window happens to fall with a strong impact
against machine, while some part of your body
is extended out of cabin, it can result in bodily
injury.

2-60
Closing the Window
WARNING
Be careful that your hands are not caught in window frame.
1. Lower bucket or work tool to ground. 2 1
2. Move safety lever (Figure 138) to "LOCK" position, and FG014392

stop engine. Figure 140
3. Holding upper handles (1, Figure 140) of front window with
left and right-hand, pull lock levers (2, Figure 140) to
release the lock.
4. Push window forward, and lower it slowly.
5. When bottom of the window, reaches top of front bottom
window, push front window to engage lock (2, Figure 139).
6. Check that lock levers are securely latched in lock position.
Front Bottom Window

1
The front bottom window can be removed and stored in the rear
of the cabin.
1. After stowing the front upper window in the cabin ceiling,
remove bottom window (1, Figure 141) from cabin in
direction of arrow.
FG014393
Figure 141
2. Set bottom window in rubber holders (2, Figure 142)

behind operator's seat. Secure window with left and right
knobs (3) with push button (4).
WARNING 4 3

Never have wet hands when handling a window. Never
drop window or let it come into contact with other FG014394
parts of the machine.
Figure 142

2-61
DOOR SIDE LATCH
1. 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
2. To release door from side of cabin, push latch lever (1,

Figure 144) down. The latch lever is to the left of operator's
seat.
FG014396
Figure 144

2-62
CABIN STORAGE 2
COMPARTMENTS
There are two storage compartments behind the operator's seat.
1
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".
FG014397
Figure 145
There is a separate small tray (3, Figure 146) on the right side of
operator's seat.
FG014398
Figure 146
ASHTRAY
1
An ashtray (1, Figure 147) is on the right side of the operator's
seat. Always close ashtray after putting out a cigarette.
FG014399
Figure 147

2-63
SUN VISOR 3
The sun visor can be used to reduce the amount of sunlight 1

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).
In case of reducing the amount of sunlight coming through the
ceiling cover, pull down the bar and hang on the hook (3, Figure 2
148). FG014400
When not wanting protection, unhook the bar from the hook. Figure 148
This will allow the sun visor to retract.
NOTE: Do not allow the visor to roll back up without holding
it. Not holding it can result in damage to the visor and
retract mechanism.
HANGER
1
A hanger (1, Figure 149) is located on upper left side of
operator's seat.
WARNING
Do not hang anything that will easily fall down, or will FG014401
impair your view out of the cabin. Figure 149
CUP HOLDER
1
There is a cup holder on the right side of the operator's seat (1,
Figure 150). Open the access cover and lower it to a horizontal
position.
FG014402
Figure 150

2-64
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.
FG014380
WARNING Figure 151

Protect your eyes when breaking the glass.

2-65
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.
1
2
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.
1 2
FG015912
Figure 153
Engine Cover
Open the cover and slide prop rod (1, Figure 154) in slot (2) until 2
it locks in notch at end of slot to support cover.
1
To close cover, move end of prop rod out of notch so it can slide
in slot.
FG014405
Figure 154

2-66
3Operation
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.
Hour Load
Maintain about 80% load
For first 50 hours of operation. of full capacity (Engine
rpm: 80% of rated rpm)
After first 50 hours of operation. Full load
If machine is used at full load before it is broken in, it may affect

the life cycle and safe running operations. This could lead to
problems later.
NOTE: 1. Check daily for leakage of coolant, fuel, engine
oil and hydraulic oil.
2. Inspect all lubricants daily, add appropriate
lubricants as required.
3. During operation, monitor all instruments and
gauges from time to time.
4. Avoid an extreme engine load.
5. Operate unit at 80% load until engine and all
other components are at operating temperature.
6. Check that work equipment is operating
normally during operation.
7. Check machine for loose parts or for damage
that may have occurred during shipping.
8. Check for loose wiring or terminals, check
gauge operation and battery electrolyte level.
DX235LCR Operation
3-1
Lubrication and Filters
1. Change engine oil and replace oil filter after first 50 hours
of operation.
2. Change swing reduction device oil after first 250 hours of
operation.
3. Change hydraulic oil return filter after first 250 hours of
operation.
4. Replace travel and reduction gear oil after first 250 hours
of operation.
NOTE: For the replenishment of oil or grease, refer to
"Inspection, Maintenance and Adjustment" on
page 4-1 of this manual.
STARTING AND STOPPING THE

ENGINE
Inspection Before Starting Engine
WARNING
If a flammable materials such as leaves, paper, etc. are
allowed to accumulate on high temperature components,
such as the engine muffler and turbo, a fire can occur. Fuel,
lubricant and hydraulic oil leaks, can cause a fire. If there is
anything wrong, perform the appropriate corrective action.
Before starting engine, inspect the following items:

1. Electric system - Check for damaged electric cables, and
loose or missing connectors.
2. Fuel system - Drain water and sediment from fuel tank and
water separator.
3. Hydraulic system - Check for hydraulic oil leaks, damaged
tubing and hoses, and interference points of components.
4. Lubrication - Perform all daily and periodic maintenance
services. Perform services according to reading shown on
hour meter.
5. Safety - Perform a machine walk-around. Make sure that
no one is under the machine or performing any
maintenance on it, before starting engine.
6. After starting machine - Check that all operational controls
and components, are in proper operating condition, and
are functioning correctly. Stop operation and correct any
malfunction before continuing work.
Operation DX235LCR
3-2
Operational Checks Before Starting
Engine
WARNING
Unlock
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
1. Move safety lever to "LOCK" (Figure 1).
2. Fasten seat belt. Check for proper operation and condition.
3. Set all operation levers in "NEUTRAL".
NOTE: Be careful not to touch any switches when
starting engine.
4. Rotate the starter switch to "I" (ON) position (Figure 2).
Check all indicator lights. A warning buzzer will sound for
about two seconds. After two seconds, all lights except the
O I
following will turn "OFF".
• Charging warning light
• Engine oil pressure warning light
• Engine coolant temperature gauge
• Fuel gauge
• Hydraulic oil temperature gauge FG000084
Figure 2
• Engine rpm (0 rpm) digital readout
NOTE: If all the indicator lights do not come "ON" when
the key is first turned, there is a problem.
DX235LCR Operation
3-3
Engine Start
WARNING
Start the engine after sounding horn and making sure there
are no people or obstacles in the area.
1. Perform all steps in "Operational Checks Before Starting

Engine" on page 3-3.
2. Set engine speed control dial slightly above "LOW IDLE"
(Figure 3).
3. Sound horn.
HAOB34L
Figure 3
4. Enter password.
NOTE: If the security system is "LOCKED", a four-digit
password will be required to start the engine. If the
system is "UNLOCKED", no password will be ENTER
required and this display screen will not appear. PASSWORD
FG013717
Figure 4
" "
5. Turn starter switch to (START) position (Figure 5).
Engine should start in approximately five seconds. O I
WARNING
If the engine does not start after approximately fifteen
seconds of cranking, release the starter switch. Wait
about five minutes and repeat above step.
FG000085
Figure 5
6. After engine has started, release key. Key will return to "I"
(ON) position (Figure 5).
7. Follow procedures in "Hydraulic System Warm-up" on
page 3-9.
3-4
8. After warming unit, check all operating indicators to make
4 5 6 7
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:
PWR
1 2 3 FG013731
Figure 6
No. Instrument Panel Light or Gauge Indicator Reading

1 Engine Coolant Temperature Gauge Blue Range
2 Fuel Gauge Blue Range
3 Hydraulic Oil Temperature Gauge Blue Range
4 Charging Warning Light OFF
5 Engine Oil Pressure Warning Light OFF
6 Engine Coolant Temperature Warning Light OFF
7 Engine Check Warning Light OFF
9. Check color of exhaust smoke.

• No color or light blue - Engine is running in good
condition.
• Black - Incomplete combustion. Check cause.
• White or dark blue - Engine is burning engine oil.
Check cause.
10. Check for usual engine vibration and noises. If any are
heard or felt, investigate cause.
NOTE: If engine coolant temperature gauge pointer
moves into the red zone, the engine coolant
temperature warning light will turn "ON", a
warning buzzer will sound, and the engine
speed will be automatically reduced. Allow the
engine to run at low idle speed until temperature
gauge registers in the blue zone again. When
the blue zone is reached, allow the engine to
idle for an additional three - five minutes before
shutting down the engine. If not allowed to idle,
heat surge may develop which will damage the
engine. Allowing the engine to idle will dissipate
heat. Check the coolant level, look for a loose
fan belt, inspect for debris around radiator, and
so on.
DX235LCR Operation
3-5
Cold Weather Starting
WARNING
DO NOT USE STARTING FLUIDS. The preheat system could
cause the starting fluid to explode. Starting fluids should
never be used.
1. Perform all steps in "Operational Checks Before Starting

Engine".
2. Set engine speed control dial slightly above "LOW IDLE"
(Figure 7).
3. Sound horn.
HAOB34L
Figure 7
4. Turn starter switch to "I" (ON) position (Figure 8). When

preheat cycle is completed, the preheat indicator light (1,
Figure 9) will turn "OFF".
O I
FG000084
Figure 8
PWR
FG013732
Figure 9
3-6
5. After the preheat completion, immediately turn starter
switch to " " (START) position (Figure 10). Engine O I

should start in approximately five seconds.
WARNING
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.
6. After engine has started, release key. Key will return to "I"
(ON) position (Figure 10).
7. After the engine starts, 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, stop engine.
8. Follow "Hydraulic System Warm-up" procedures in this
section. (See page 3-9)
Starting Engine With a Booster Cable
WARNING
1. An explosive gas is produced while batteries are in
use or being charged. Keep flames or sparks away
from the battery area.
HAOA440L
2. Charge batteries in a well ventilated area.
Figure 11
3. Always wear eye protection when starting a machine
with jumper cables.
4. Improper jump starting procedures can cause an
explosion resulting in personal injury.
5. Jump start vehicles on dry ground or concrete. Do not
jump start the machine on a steel floor, because the
floor is always grounded.
6. When starting from another machine, make sure the
machines do not touch.
7. Always connect the auxiliary battery positive (+)
terminal too depleted battery positive (+) terminal first.
Then connect auxiliary battery negative (-) terminal to
the frame of the depleted battery machine second.
8. Connect positive cable first when installing cables and
disconnect the negative cable first when removing.
DX235LCR Operation
3-7
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

1
1. Stop engine of the machine on which booster batteries (3, RED
Figure 12) are mounted.

2. Connect one end of red cable (1, Figure 12) to the positive
(+) terminal of the machine batteries (4), and the other end
to the positive (+) terminal of the booster batteries.
3. Connect one end of black cable (2, Figure 12) to the 3 4
negative (-) terminal of the booster batteries (3), and then BLACK
make ground connection to the upper frame (5) of the 2 5

machine to be started with the other end of black (-) cable ARO0440L
(2, Figure 12). When making the last connection to upper Figure 12
frame, be sure to connect the cable end as far away from
the machine batteries as possible. DO NOT CONNECT
DIRECTLY TO THE NEGATIVE BATTERY TERMINAL.
4. Start the engine.
Disconnecting the Booster Batteries

1. Disconnect black negative (-) cable (2, Figure 12) from the
machine frame (5) first.
2. Disconnect the other end of black negative (-) cable (2,
Figure 12) from the booster batteries (3).
3. Disconnect red positive (+) cable (1, Figure 12) from the
booster batteries (3).
4. Disconnect red positive (+) cable (1, Figure 12) from the
machine batteries (4).
3-8
Hydraulic System Warm-up
WARNING
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° - 175°F). Make sure to follow the procedures listed
here for hydraulic fluid warm-up.
1. Run engine for approximately five minutes set at the
middle of the speed range, without a load.
HAOB410L
Figure 13
2. Move safety lever to "UNLOCK" position.
Unlock
Lock EX1300566
Figure 14
3. Slowly cycle boom, arm and bucket cylinders about five

times without a load to circulate the oil through the system.
Do this for five minutes.
4. Check for clearance and fully raise the front attachment.
Swing clockwise 3 revolutions. Swing counterclockwise 3
revolutions.
5. Travel forward and reverse at low speed for two
revolutions of the drive sprocket.
FG015914
Figure 15
DX235LCR Operation
3-9
Hydraulic System Warm-up – Cold
Weather
1. Run engine at "LOW IDLE" (no load) for five minutes
(Figure 16).
HAOB290L
Figure 16
2. Run engine for approximately five minutes set at the

middle of the speed range, without a load (Figure 17).
HAOB410L
Figure 17
3. Move safety lever to "UNLOCK" position.
Unlock
Lock EX1300566
Figure 18
4. Slowly cycle boom, arm and bucket cylinders about five

times without a load to circulate the oil through the system.
Do this for five minutes.
FG015914
Figure 19
3-10
5. Set engine speed control dial to "HIGH IDLE" (Figure 20).
6. 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.
7. Check for clearance and fully raise the front attachment.
Slowly swing clockwise 3 revolutions. Slowly swing
counterclockwise 3 revolutions.
8. Travel forward and reverse at low speed for two
revolutions of the drive sprocket.
HAOB550L
Figure 20
Stopping Engine
NOTE: Allow engine to idle for three - five minutes before
shutting down the engine. If not allowed to idle, heat
surge may develop which will damage the engine.
Allowing the engine to idle will dissipate heat.
1. Park machine on firm and level ground.
2. Lower front end attachment to ground and make sure all
operating controls are in "NEUTRAL".
FG015915
Figure 21
3. Move safety lever to "LOCK" position (Figure 22).
Unlock
Lock EX1300566
Figure 22
4. Set engine speed control dial to "LOW IDLE" (Figure 23).

Allow engine to idle for three - five minutes.
HAOB290L
Figure 23
DX235LCR Operation
3-11
5. Stop engine by turning key to "O" (OFF) position (Figure
24). O I
6. Remove key from starter switch.
FG000175
Figure 24
Check and Confirmation After Stopping

Engine
1. Repair excavator, if there are any coolant or oil leaks.
2. Inspect front attachment and under carriage for abnormal
appearances. Correct any problems.
3. Fill fuel tank.
4. Get rid of any accumulated flammable materials such as
leaves and paper etc. in engine compartment.
5. Clean all mud, etc. from undercarriage and tracks. Make
sure that all steps and hand holds are clean, and that
operator's cabin is clean.
3-12
SAFETY LEVER
WARNING
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".
Especially, when adjusting the seat, control stands, or
raising the front window, lower window, or ceiling cover,
never forget to lock the safety lever in its "LOCKED"
position.
Be careful not to move the work levers (joysticks) when moving

safety lever.
1. Push safety lever (Figure 25) down into "LOCKED"
position. When safety lever is in the "LOCKED" position,
the front attachment, swing and travel movement will be
disabled even though a lever is moved.
NOTE: Lower bucket (front attachment) to ground.
Place all control levers in "NEUTRAL" and stop
engine, before using the safety lever. Unlock
2. Move safety lever (Figure 25) on "RELEASE/UNLOCK"

position, by pulling it up before starting work.
NOTE: When the engine is not running, but the safety Lock EX1300566
lever is "RELEASED" and the starter key is Figure 25
tuned "ON", moving the work levers (joysticks)
can result in movement. The charged
accumulators in the system will provide pilot
pressure for control valve spool movement.
DX235LCR Operation
3-13
TRAVEL
WARNING
1. 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). In this case,
the response of the travel levers will be the reverse of
normal operation.
2. Before moving, make sure that there are no personnel
in the way or on the machine. Sound the horn to alert
workers that you are about to move the machine.
3. Be sure the path is clear during travel.
4. Use extreme caution when reversing travel. Be sure
there is a clear path behind the machine.
5. Make sure to operate the travel control levers
smoothly to avoid sudden starts or stops.
6. Before leaving the operator's seat, make sure to lock
out all control systems and stop engine to avoid
accidental activation.
3-14
Automatic Travel Speed Control
WARNING
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. Only change travel mode after
coming to a complete stop.
Two travel speed ranges can be selected by using the travel

speed selector switch on the control panel (Figure 26).
"O" (LOW) - In this position low travel speed and a higher torque
O
are selected.
I
II
"I" (HIGH) - In this position high travel speed and a lower torque
are selected.
"II" (AUTOMATIC) - Setting the control at the "II" position
enables the machine to change to a different speed range
automatically. This change happens automatically depending on
the hydraulic oil pressure in the travel circuit. When hydraulic oil FG000023
pressure rises, the travel speed is automatically set to low. Figure 26
An example is if the machine is traveling on a flat, solid surface,
the higher speed range would be used. When a slope is
encountered, the speed drops and the travel circuit hydraulic
pressure rises, causing the control circuit to shift to the higher
torque, lower speed range.
DX235LCR Operation
3-15
Travel Control Lever Operation
1. 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
2. Pivot turns (Figure 28) are made by rotating only one track
forward or backward. The machine will pivot on the
nonmoving track.
"X"
FG000304
Figure 28
3. Spin turns (Figure 29) are made by rotating one track

forward and one track backward. The machine will spin
around its center point, thus counterrotating.
"X"
FG000305
Figure 29
4. Stopping travel (Figure 30) - Returning travel levers to

"NEUTRAL" position will automatically apply brakes and
stop excavator.
"X"
FG000306
Figure 30
3-16
General Travel Instructions
1. Set engine speed control dial (Figure 31) on desired
speed.
HAOB550L
Figure 31
2. 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
3. When possible, travel on firm and level ground. Avoid

sudden movements and sharp turns.
4. When traveling on rough ground, travel at a slow speed
[1.0 - 1.5 km/h (0.62 - 0.93 MPH)]. Reduced engine speed,
to avoid shock loading the equipment. Be careful that an
excessive force is not added to equipment by touching or
climbing on rocks.
FG016063
Figure 33
DX235LCR Operation
3-17
5. On rough, frozen or uneven terrain, travel slowly.
WARNING
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. Figure 34
If excavator starts to slip or becomes unstable, lower
the bucket immediately into the ground, using it as a
brake.
Avoid working on slopes, because there is a danger of
overturning by becoming unbalance while swinging
and performing front attachment operations.
20 -
It is very dangerous to swing towards bottom of slope 30 c
m
with a loaded bucket.
In unavoidable cases level the slope with fill soil, to
make the vehicle as horizontal as possible. See Figure
34. FG015918
Figure 35
Do not travel on slopes more than 30° because of
turnover danger.
6. Travel straight up or down slopes, never diagonally across

the slope. See Figure 35 and Figure 36. Extend the arm
and lower the boom to keep the bucket about 20 - 30 cm (8
- 12 in) off the ground. If the machine starts to slide or
becomes unstable, lower the bucket to regain control. If the
engine stalls, lower the bucket, make sure that all controls
are in the neutral position and restart the engine.
NOTE: Even though engine stops on a slope, do not
m
operate swing control. The hydraulic 30C
accumulators can cause the unit to swing. 20~
FG015919
NOTE: Do not open or close operator's door on a slope.
Figure 36
Make sure door is latched.
7. If dirt or mud builds up in the track frame, raise each track
and rotate and clean that track.
CAUTION
AVOID INJURY
When using the boom and arm to lift any portion of the
machine, roll the bucket until round base is against the
ground. The angle of the arm to the boom must be at
FG016064
90°.
Figure 37
3-18
Make sure that material buildup has been cleared. See
Figure 37 and Figure 38.
8. The excavator can travel in water that comes up to center
of upper carriage rollers. Make sure that footing is solid so 90 ~ 110
the machine will not sink. See "Working in Water" on
page 3-31.
NOTE: If the machine is submerged to the point that
water or mud gets into the swing bearing or
center joint, stop machine operation. Remove
machine from the submerged location to firm, EX1300536
dry ground. Do not operate until proper
Figure 38
inspection and maintenance have been
completed. Refer to the Shop Manual or contact
your distributor.
Straight Travel Pedal (Optional)
WARNING
1. When moving the straight travel pedal forward, the
excavator will move forward in the direction of the idlers.
When the pedal is moved backwards, the excavator will
move backward in the direction of the drive sprocket.
2. Before moving, make sure there are no persons or
property in the way or on the machine. No riders.
Sound the horn to alert workers and bystanders that
you are about to move the machine.
3. Always be sure the path is clear during travel.
4. Use extreme caution when reversing travel. Be sure
there is a clear path behind the machine.
5. Operate the travel control pedal smoothly to avoid
sudden starts or stops.
6. Before leaving the operator's seat, make sure to lock
out all control systems and stop engine to avoid
accidental activation of controls.
DX235LCR Operation
3-19
Operating 1
1. Forward
2. Reverse
1
2
"X" 2
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

positioned into pedal hole.
A. Location for "UNLOCKING" (Figure 41). B
B. Location for "LOCKING" (Figure 41).

A
FG018583
Figure 41
3-20
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
maintenance.
Mode Selection
More efficient work can be done by choosing a proper power
and work mode combination, suitable to type of work and
conditions. Use the mode selection according to following guide.
Power Mode
1
1. When the starter switch is turned "ON" the power mode is
automatically defaulted to the standard setting.
2. Select a proper power mode using button (1, Figure 43)
before starting work. 1 2
3. When the power mode button (1, Figure 43) is pressed, a

signal sounds, changing the power mode to either "ON" or
"OFF". When the power mode is turned "ON", the symbol
indicates on the screen. 6 7
FG013733
Deactivate the power mode by pressing it a second time.
Figure 43
When the power mode is turned "OFF", the symbol of
standard mode indicates on the screen and the power
mode returns to the standard mode.
Mode Selection Point

• Required to perform heavy work in a short period of time.
Power Mode • Fast speed loading.
• Fast speed travel.
• General work.
Standard Mode
• Optimize fuel consumption.
• Light work.
Economy Mode • Minimize fuel consumption.
• Reduce noise.
DX235LCR Operation
3-21
Economy Mode
1. When the starter switch is turned "ON" the power mode is
automatically defaulted to the standard setting.
2. Select a proper power mode using button (2, Figure 44)
1 2
before starting work.
3. When the economy mode button (2, Figure 44) is pressed,
a signal sounds, changing the economy mode to either
"ON" or "OFF". When the economy mode is turned "ON",
6 7
the symbol appears on the screen.
2
Deactivate the economy mode by pressing it a second FG013742
time. When the economy mode is turned "OFF", the Figure 44
symbol of standard mode. Appears on the screen and the
economy mode returns to the standard mode.
Auto Idle Mode

3
1. The system will automatically reduce engine speed to idle
speed approximately four seconds after all of the control
levers are in the neutral position. When a pilot function is
activated, engine speed is automatically returned to the
1 2
preselected range.
2. When the starter switch is turned "ON", the work mode is
automatically defaulted to "AUTO IDLE".
3. When the symbol is turned "ON", the auto idle function is 6 7
activated. Deactivate the auto idle function by again FG013743
pressing the auto idle selector button (3, Figure 45). Now Figure 45
the symbol will be turned "OFF".
WARNING
Turn "OFF' auto idle function when performing work in
close operating area, i.e., work in a narrow area and
loading/unloading on or off a trailer.
3-22
Boost Mode
1. Power boost switch is used to gain maximum digging I
O
force.
II
2. 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.
Do not use this switch for more than ten
seconds.
FG000117
Figure 46 Right-hand Work Lever (Joystick)
DX235LCR Operation
3-23
Work Levers (Joysticks) (ISO Pattern) 1 5
3 4 7 8
WARNING
2 6
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
attachment.
This equipment is manufactured using the lever configuration
described in ISO standards. Do not change valving, hoses, etc.,
that would change this standard. The boom, arm and bucket
movements and swing direction of work levers (joysticks) are as
follows:
Left-hand Work Lever (Joystick) (Figure 47 and Figure 48)

4
1. Arm dump
2. Arm crowd 1 3
3. Left swing 2
4. Right swing
NOTE: The swing brake is spring applied and hydraulically
released. It is always engaged when the work lever
(joystick) is in "NEUTRAL" or the engine is stopped.
FG015922
Figure 48
NOTE: The following is not a mechanical malfunction but a

proper phenomenon of the excavator. When
operating the arm, it may stop momentarily. When
the arm is operated, the weight of the arm can cause
it to move faster than the amount of oil being
supplied.
FG015923
Figure 49
3-24
Right-hand Work Lever (Joystick) (Figure 47 and Figure 50)
5. Boom down 6
6. Boom up
7. Bucket crowd
8. Bucket dump 5
7
8
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". FG015924
Figure 50
Change Machine Control Pattern by Select 1 5

Valve (If Equipped)
3 4 7 8
WARNING 2 6

Check surrounding area before swinging. When operating a
lever while in auto idle, do it carefully, because the engine
speed will increase rapidly.
FG015921
Figure 51
NOTE: When starting work, move work levers (joysticks)

slowly and check movement of swing and front <ISO PATTERN>
attachment.
IS
The machine control pattern can easily be changed to the ISO

O
standard or to the standard backhoe loader hydraulic system

(BHL) by changing the position of the select valve (if equipped).
Use the following procedure to change the position of the select
L
BH
valve.
The select valve is located in the rear of the cabin.
1. Rotating spool to the ISO position or to the BHL position. <BHL PATTERN>
(Figure 52)
IS
O
L
BH
FG004954
Figure 52
DX235LCR Operation
3-25
Work Levers (Joysticks) (BHL Pattern)
Left-hand Work Lever (Joystick) (Figure 51 and Figure 53)

2
1. Boom down 4
2. Boom up
3
3. Left swing
4. Right swing 1
NOTE: The swing brake is spring applied and hydraulically

released. It is always engaged when the work lever
(joystick) is in "NEUTRAL" or the engine is stopped.
FG015925
Figure 53
Right-hand Work Lever (Joystick) (Figure 51 and Figure 54)

5. Arm dump
5
6. Arm crowd
6
7. Bucket crowd
8. Bucket dump 7
NOTE: The following is not a mechanical malfunction but a 8
proper phenomenon of the excavator. When
operating the arm, it may stop momentarily. When
the arm is operated, the weight of the arm can cause FG015926
it to move faster than the amount of oil being Figure 54
supplied.
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".
FG015923
Figure 55
3-26
OPERATING PRECAUTIONS
WARNING
Do not rest your feet on the travel pedals during normal
machine operation. Unexpected machine travel can occur
in this situation.
1. Before starting work, investigate terrain and soil condition.

Level ground and drain area if necessary.
2. Install window guards when working where there is a
possibility of falling rocks or other objects.
FG016065
Figure 56
3. Check strength of supported structures in advance before

working on them. If insufficient, reinforce it. If any doubt
exists about structural strength, refuse to operate unit.
4. It is possible that the boom, arm or bucket may come into
contact with the upper or lower structure of the machine.
There are digging conditions which could allow this to
happen.
FG015927
Figure 57
5. Do not continually "bottom out" the hydraulic cylinders.

Machine damage can occur if the cylinders are fully
extended or retracted, example: arm cylinder fully retracted
and the bucket cylinder is extended to rotate the bucket
into the ground.
FG015928
Figure 58
DX235LCR Operation
3-27
6. Do not use machine travel or swing when the bucket is in
the ground to provide additional breakout force. See Figure
59.
FG015929
Figure 59
7. Do not use weight of machine to provide additional

breakout force. See Figure 60.
8. When working on soft or muddy ground, make sure that
the machine is not sinking.
FG015930
Figure 60
9. When working close to the excavated edge, make sure

that ground the machine is sitting on is solid. Keep the
travel motors (1, Figure 61) to the rear. See Figure 61.
FG015931
Figure 61
10. Do not excavate underneath the machine. See Figure 62.
FG015876
Figure 62
3-28
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. Do not use the bucket as a hammer or ramming device.

This is dangerous and causes damage to the front
attachment. See Figure 65.
FG015933
Figure 65
14. Do not dig with the excavator tracks raised. This can result
in structural and mechanical failures.
FG015934
Figure 66
DX235LCR Operation
3-29
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. Return levers to neutral by
hand. Do not let them snap back to neutral on their
own.
FG000213
16. If the optional long fronts or attachments or heavy duty
front end attachments are used, the machine balance will Figure 67
be altered. Follow these additional operating precautions.
WARNING
Do not travel downhill with the front end attachments
raised.
Do not travel across slopes; travel straight up or
downslope.
Use extreme caution when swinging the upper frame
when positioned on a slope.
Allow extra swing stopping room. The additional
momentum generated by the longer or heavier front
end equipment will increase the amount of time
needed to stop the swing motion.
Make sure that all optional equipment has been
authorized and installed properly.
17. Do not move dirt or objects by swinging the excavator into

them. This can result in structural and mechanical failures.
3-30
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

upper roller (1, Figure 69).
If swing bearing gets wet, immediately grease it until all old
grease is purged from bearing.
If water gets into swing gear housing, drain water immediately
by removing lower inspection cover. Apply new grease.
After working in water, purge old grease on bucket pins.
1
FG015936
Figure 69
DX235LCR Operation
3-31
PARKING EXCAVATOR
WARNING 120

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
1. Park excavator on firm and level ground. Lower bucket or

work tool to ground as shown in Figure 71.
FG015915
Figure 71
2. Set engine speed control dial on "LOW IDLE".
HAOB290L
Figure 72
3. If you touch the operation lever unintentionally, it may

create a serious accident. Before leaving operator's seat,
move safety lever to "LOCK" position.
Unlock
Lock EX1300566
Figure 73
3-32
TOWING PROCEDURE Cloth
WARNING
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.
Attach chain or wire rope to track frame as shown in Figure
74.
Insert protective material such as thick cloths between
track frame and wire rope to prevent the wire rope from
being damage.
Towing Wire
FG015010
Figure 74
IMPORTANT
Use shackle hook on track frame to only haul objects that
weigh less than 7 metric tons (7.71 U.S. Tons). Never use it
to haul objects over 7 metric tons (7.71 U.S. Tons).
DX235LCR Operation
3-33
HYDRAULIC ATTACHMENTS
(OPTIONAL)
Breaker Operation
IMPORTANT
If a hydraulic breaker and piping is installed without
DOOSAN's authorization, it may create a serious
malfunction which will not be covered under the excavator
warranty.
Selection of Hydraulic Breaker

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

1. When installing hydraulic breaker, assemble according to
drawings provided with kit.
2. If breaker is taken off excavator, be sure to plug and cap all
hoses and tubing to prevent contamination from entering
hydraulic system.
3. Plug and cap all connectors and fittings on breaker to
prevent contamination.
4. Check all hydraulic connections for signs of leaks or loose
components before starting operation.
3-34
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.
1. Make sure to read and understand the breaker user's
manual.
2. Inspect all mechanical and hydraulic connections.
3. Do not use the breaker as a hammer. See Figure 75.
Do not drop breaker from extreme heights.
The breaker is relatively heavy and drops fast. Do not drop
breaker from extreme heights or damage to upper
structure can result.
FG016066
Figure 75
4. Do not operate the breaker with the boom or arm cylinders

fully extended (bottomed out). See Figure 76.
Leave over 100 mm (4 in) of clearance between rod end of
cylinder and cylinder head. This will help prevent damage
to cylinders during breaker operation.
FG016067
Figure 76
5. Do not use the breaker if the hydraulic hoses vibrate

excessively. See Figure 77. Check the breaker's hydraulic
accumulator (1) for damage and repair as required. If 1
excavator is operated under this condition, structural and
hydraulic components can be damaged.
FG016068
Figure 77
DX235LCR Operation
3-35
6. 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
7. Do not any lifting or towing with a breaker. See Figure 79.
FG016069
Figure 79
8. Operate the breaker only to the front and rear of the

excavator. Do not use the breaker to either side of the
excavator. Do not swing the breaker from side to side
when operating it. See Figure 80.
WARNING
Operating a breaker with the upper body turned 90° to
HAOB990L
the tracks can result in tipping over the machine or
Figure 80
reduction in service life.
9. Do not curl the breaker tool tip into the arm or boom when
traveling or parking the excavator. See Figure 81.
FG016070
Figure 81
3-36
To activate breaker
1. Set breaker selector switch to "II" (BREAKER) position. I
O
2. Press lower button on top of right-hand work lever II
(joystick) to activate hydraulic breaker.
3. 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

1. Cap pipe on arm end, using a cap capable of handling
370 kg/cm2 (5,263 psi) under the condition of
disconnecting hose to hydraulic breaker.
2. Adjust pump pressure using activating the breaker, and
watching the pressure displayed on the instrument panel.
Press the display selector button to show digital pressure
reading. (A separate pressure gauge is not required.)
3. Adjust the relief valve pressure by turning the adjustment
screw of breaker relief valve. The relief valve is installed on FG014414
the left side of the upper structure behind the boom. (Do Figure 83
not use the overload relief valve on the lower part of control
valve for the breaker relief valve.)
WARNING
If the relief valve pressure is adjusted while the
hydraulic breaker is connected, there is possibility
that a high-pressure spike or setting could break a
hose or pipe. Personal injury or death could result
from a hydraulic hose or pipe failure.
DX235LCR Operation
3-37
Hydraulic Oil and Filter Service Intervals
When using a hydraulic breaker, the viscosity breakdown and
contamination of hydraulic oil is faster because the work
condition is more severe than during normal digging work. To
prevent the hydraulic components (especially pump) from
having a shortened life cycle, replace the hydraulic oil and main
hydraulic oil return filter using the following schedule.
Attachment Operation Rate Hydraulic Oil Filter

250 Hours (First Replacement)
Bucket Work 100% 2,000 Hours
1,000 Hours (After First Replacement)
Hydraulic Breaker
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.
100
105 116 551
106 144 614

80
BREAKER OPTION RATE (%)
112 171 FILTER 692

(First Replacement)
119 214 782
60
128 275 893

HYDRAULIC OIL
137 335 1028
40
FILTER
156 412 (After First Replacement) 1196
175 500 1400

20
206 635 1658
0 500 1000 1500 2000
MACHINE OPERATING HOURS

FG000767
Figure 84
NOTE: The replacement intervals of hydraulic oil and filter

depend upon the amount of time the hydraulic
breaker is being used. These intervals must be
followed as opposed to regularly scheduled
maintenance.
3-38
ADJUSTING THE PUMP FLOW
NOTE: For further information, see "Flow Control" on
page 2-42.
1. On the instrument panel, press the flow control button
, the flow control screen (Figure 85) will be displayed.
2. Use "UP" ( ) or "DOWN" ( ) buttons to adjust flow rate.

3. Press "SELECT" ( ) button, to return to normal display
screen and save the flow rate setting.
FLOW CONTROL
E F
C H C H
1 2 3 4 5
: APPLY ESC: CANCEL

6 7 8 9 0
<Normal Display> <Flow Control Display>

FG013831
Figure 85
Setting Flow Rate (l/min)

0 48.5
1 57
2 66
3 69
4 78.5
5 90
6 96.5
7 106.5
8 108
9 114
10 114
DX235LCR Operation
3-39
Two-way Pedal Valve (Optional)
Activating Shear with Pedal Valve

1. Select shear with the selector switch of the right panel. 1
2. 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.
3. Before operating attachment, be sure to check function 2
controlled by direction of pedal movement.
EX1400015
Figure 86
Activating Breaker with Pedal Valve

1. Select "BREAKER" with selector switch on right panel.
2. Rotate knob (3, Figure 87) 120° for stopper (4, Figure 87) 5
be fastened to (5, Figure 87).
3. In the condition that (2, Figure 86) is fastened, activate the
breaker to the direction (1, Figure 86).
4 3
EX1400016
Figure 87
Adjusting the Stopper

1. Rotate knob (3, Figure 87) in the direction of the arrow,
then the pedal is activated according to the display caused
by (3, Figure 87) knob rotation.
CAUTION
Shear
AVOID INJURY
When operating breaker or shear when using button Lock
on a joystick, and it is not to be controlled by the
Breaker
pedal, be sure to keep the stopper in the "LOCK"
position in order for the pedal not to be activated. EX1400018
Figure 88
3-40
Rotating Pedal Valve (Optional)
1
Attachment Rotating by Using the Pedal Valve
1. Pressing end (1, Figure 89) is used to turn clockwise.
2. Pressing end (2, Figure 89) is used to turn
counterclockwise.
NOTE: Before activating the pedal, be sure to check 2
the function of the attachment.
FG000405
Figure 89
Locking the Pedal

When rotating is not needed, the pedal can be locked by using
the prop rod (3) locking device.
Locking is completed when the top end of the prop (3) is 3
positioned into pedal hole.
FG000406
Figure 90
A. Location for "UNLOCKING".

B, Location for "LOCKING".
FG000407
Figure 91
Attachment Rotation Using the Left-hand Work Lever

2
(Joystick)
1
For a machine equipped with an attachment that rotates,
rotation is activated while one of the control buttons is being
pressed on top of the left-hand work lever (joystick).
There are three buttons on top of the left-hand work lever. The
left and right ones are for controlling rotation.
NOTE: The middle button is for the horn.
Left button is for counterclockwise rotation, and the right one is
FG015905
for clockwise rotation.
Figure 92 Left-hand Work Lever (Joystick)
DX235LCR Operation
3-41
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.
Ensure the following safety working devices equipped and
operated.
• Lifting eye for load hooking.
• Hose burst protection on both boom and arm.
• Overload warning devices.
To prevent injury, do not exceed the rated load capacity of the
machine. If the machine is not on level ground, load capacities
will vary.
Short slings will prevent excessive load swing.
Use the lifting eye on the bucket that is provided to lift objects.
Always try to maintain the lifting eye (Figure 93) straight below
the center line of the arm and bucket pin. In this manner the
weight of the load is being primarily held only by the pin, and not
by the bucket cylinder, link, and link pins.
When a lifting eye is used, the sling/lifting device must be
fastened to the eye in a manner that will not allow it to come
loose.
The most stable position is over the corner of the machine.
For best stability, carry a load as close to the ground and
machine as possible. HAAD3830
Lift capacity decreases as the distance from the machine swing Figure 93
center line is increased.
3-42
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
does not exceed the machine LOAD RATING CHART at the FRONT LIFT
radius at which it is to be lifted. ZONE
It is recommended that you feel your way into any lift as a

precaution against tip-over. One method is to position the boom
at 90° over the side of the machine. Slowly lift the load until it SIDE LIFT SIDE LIFT
clears the ground. A lift over the side is the most unstable, and ZONE ZONE
as the load is swung into the front zone of the excavator it will
become more stable. DO NOT INCREASE SWING RADIUS
AFTER THE LOAD IS LIFTED.
REAR LIFT
DANGER ZONE
HAAD3842
AVOID DEATH Figure 94

If a load is picked up from the front zone and swung into the
side zone, a tip-over could result causing a deadly or fatal
injury.
Lifting Known Weight

The load chart is the governing factor when lifting known
weights. It is recommended that you feel your way into any lift as
a precaution against tip-over. Whenever possible, lift and swing
payloads between the front idler area.
Pick and Carry

The machine can pick and carry payloads without added labor.
We recommend when traveling with a suspended payload, you
evaluate the prevailing conditions and determine the safety
precautions required in each case. The following factors must be
considered before attempting to pick and carry a load.
Align the boom with the forward direction of machine travel.
Maintain this boom position when turning the machine. Turn only
when necessary, at the slowest speed, and at a wide turning
radius.
1. Use the shortest lifting radius distance possible.
2. Keep the load as close to the ground as conditions will
permit.
3. Provide tag lines to prevent load from pendulating.
Pendulating can cause a change in radius. A change in
radius could exceed the load chart rating or cause a tip
over condition.
4. Govern travel speed to suit conditions.
5. Avoid sudden starts and stops.
DX235LCR Operation
3-43
OPERATION UNDER UNUSUAL
CONDITIONS
NOTE: See "Maintenance in Special Conditions" on
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.
Warming up engine for a short period may be necessary to
avoid operating with sluggish or reduced working capacity. The
jolting shocks and impact loads caused by bumping or
bottoming boom or attachment could cause severe stress in
very cold temperatures. Reducing work cycle rate and workload
may be necessary.
If machine is to be operated in extremely cold weather
temperatures, certain precautions must be taken. The following
paragraphs detail checks to be made to be certain machine is
capable of operating at these temperatures.
1. Preheat the engine before startup.
• Preheat the engine before startup. Wait 3 to 4
seconds after preheating until voltage of the battery
return, and then actuate the key switch.
2. Keep batteries fully charged to prevent freezing. If distilled
water is added to batteries, run engine at least one hour to
mix electrolyte solution. 
When temperature drops below -10°C, efficacy of the
battery is reduced accordingly. Insulation of the battery
prevents reduction of efficacy, and supports improvement
of starting power of the starter.
WARNING
Explosion of the battery can cause serious injury or
death. Never attempt to directly heat the battery with
open fire.
3. Keep engine in good mechanical condition for easy starting

and good performance during adverse weather.
4. Use engine oil with proper specifications for expected
temperatures. Refer to "Table of Recommended
Lubricants" on page 4-6, in this manual or Shop Manual for
details.
3-44
5. 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. Periodically remove water from
the fuel tank, drain water from the filter, and replace the
filter upon regular basis. To prevent fuel from being
clogged due to formation of wax in fuel, make sure that
wax formation point of fuel is lower than atmospheric
temperature.
WARNING
Explosion of the fuel tank may cause serious injury or
death. Never attempt to directly heat the fuel tank with
open fire.
6. Lubricate entire machine according to "Lubrication and

Service Chart" on page 4-10, in this manual or lubrication
chart on machine.
7. Start engine and allow it to reach normal operating
temperature before operating.
• If mud and ice collects and freezes on any of moving
parts while machine is idle, apply heat to thaw frozen
material before attempting to operate machine.
• Operate hydraulic units with care until they have
reached a temperature which enable them to operate
normally.
• Check all machine controls and functions to be sure
they are operating correctly.
8. An extra outer air filter must be kept in operator's cabin to
replace element that could become iced and cause
restricted airflow to engine.
9. Clean off all mud, snow and ice to prevent freezing. Cover
machine with a tarp if possible, keep ends of tarp from
freezing to ground.
Operation in Extreme Heat

Continuous operation of the machine in high temperatures can
cause the machine to overheat. Monitor engine and
transmission temperatures and stop machine for a cooling-off
period whenever necessary.
1. Make frequent inspections and services of the fan and
radiator. Check coolant level in radiator. Check grills and
radiator fins for accumulation of dust, sand and insects
which could block the cooling passages.
DX235LCR Operation
3-45
A. 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.
B. 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.
2. Check level of battery electrolyte daily. Keep electrolyte
above plates preventing damage to batteries. Use a
slightly weaker electrolyte solution in hot climates. Dilute
1.28 specific gravity electrolyte as issued to 1.20 - 1.24
specific gravity readings at full charge. Recharge batteries
whenever they reach a 1.16 specific gravity reading.
Batteries self-discharge at a higher rate if left standing for
long periods at high temperatures. If machine is to stand
for several days, remove batteries and store in a cool
place.
WARNING
Do not store acid type storage batteries near stacks of
tires; the acid fumes have a harmful affect on rubber.
3. Service fuel system as directed in "Engine Fuel System"

Section 5, of this manual. Check for water content before
filling fuel tank. High temperatures and cooling off cause
condensation in storage drums.
4. Lubricate as specified in "Periodic Service Chart and
Table" Section 4, in this manual or Lubrication Decal on
the machine.
5. Do not park machine in sun for long periods of time. When
practical park machine under cover to protect it from sun,
dirt and dust.
A. Cover inactive machine with tarpaulin if no suitable
shelter is available. Protect engine compartment,
transmission and hydraulics from entrance of dust.
B. In hot, damp, climates corrosive action will occur on
all parts of the machine and will be accelerated
during the rainy season. Rust and paint blisters will
appear on metal surfaces and fungus growth on other
surfaces.
C. Protect all unfinished, exposed surfaces with a film of
preservative lubricating oil. Protect cables and
terminals with ignition insulation compound. Apply
paint or suitable rust preventive to damaged surfaces
to protect them from rust and corrosion.
3-46
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.
1. Keep cooling system fins and cooling areas clean. Blow
out with compressed air, if possible, as often as necessary.
WARNING
Wear goggles when using compressed air.
2. Use care when servicing fuel system to prevent dust and

sand from entering the tank.
3. Service the air cleaner at frequent intervals, check air
restriction indicator daily and keep dust cup and dust valve
clean. Prevent dust and sand from entering engine parts
and compartments as much as possible.
4. Lubricate and perform services outlined on current
lubrication chart on machine and "Lubrication Chart and
Table" Section 4. Clean all lubrication fittings before
applying lubricant. Sand mixed with lubricant becomes
very abrasive and speeds wear on parts.
5. Protect machine from dust and sand as much as possible.
Park machine under cover or protect with tarpaulin to keep
dust and sand from damaging unit.
Operation in Rainy or Humid Conditions

Operation under rainy conditions is similar to that as in extreme
heat procedures listed previously.
1. Keep all exposed surfaces coated with preservative
lubricating oil. Pay particular attention to damaged or
unpainted surfaces. Cover all paint cracks and chip marks
as soon as possible to prevent corrosive effects.
DX235LCR Operation
3-47
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.
1. When exposed to salt water, dry machine thoroughly and
rinse with fresh water as soon as possible.
2. Keep all exposed surfaces coated with preservative
lubricating oil. Pay particular attention to damaged paint
surfaces.
3. Keep all painted surfaces in good repair.
4. Lubricate machine as prescribed on lubrication chart on
machine or "Periodic Service Table and Chart" Section 4,
in this manual. Shorten lubricating intervals for parts
subject to exposure to salt water, if found necessary.
Operation at High Altitudes

Normally, operation of machine at high altitudes will be as
outlined in extreme cold. Before operating at high altitudes,
engine fuel and air mixture may have to be adjusted according
to appropriate engine manual.
1. Check engine operating temperature for evidence of
overheating. The pressure cap on radiator must make a
perfect seal to maintain coolant pressure in the system.
3-48
4Inspection, 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. The service cycles may need to be
shortened depending on the working conditions.
Extremely hot or dusty conditions will require more
frequent service. Operational hours are determined
by the amount of time accumulated on the engine
hour meter on the control console in the cabin. HAOA601L
Figure 1
NOTE: Besides the normal hour meter, the multifunction

gauge can be used to keep track of the hours on
individual filters. See "Filter/Oil Info" on page 2-37.
E F
C H C H
1 2 3 4 5
6 7 8 9 0
FG013662
Figure 2
DX235LCR Inspection, Maintenance and Adjustment

4-1
Product Identification Number (PIN)
Location
A PIN number, is stamped on the upper frame, under the boom
foot (Figure 3). It is also stamped on the product identification
plate (Figure 4 or Figure 5) on outside of the cabin on right.
NOTE: 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.
FG001447
Figure 3
Doosan Infracore Co., Ltd.

7-11, Hwasu-dong, Dong-gu,
Incheon, Korea
MODEL
⣆㔲ᬯ
PRODUCT IDENTIFICATION NUMBER

⣆㔲#⎇ᵮ#ᴲ㛢
MADE IN KOREA 950209-02977
FG028807
Figure 4
Machine Type
Model Name
Product
Identification
Number
Operating
950205-01325A
Engine
Power kW Mass kg
Year of First Year
Construction of Service
Doosan Infracore Co., Ltd.
7-11, Hwasu-dong, Dong-gu,
Incheon, Korea Made in Korea
EX1300306
Figure 5
Inspection, Maintenance and Adjustment DX235LCR

4-2
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.
Please make note of these numbers and their locations. These
will be required whenever warranty service work is requested.
FG006440
Figure 6
Safety Precautions
1. Make sure to lock out the hydraulic controls and post a
notice (Warning Tag) that the machine is being serviced to
prevent any unauthorized operation.
2. Make sure to clean up any fluid spills, especially around
the engine.
3. Inspect all fuel lines to make sure that fittings, lines, filters
and O-rings, etc., are tight and are not showing signs of
wear or damage.
4. If the inspection or test procedure requires that engine be
running, make sure to keep all unauthorized personnel
away from the machine, and that all industry standard
safety precautions are followed.

4-3
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.
1. Park on firm and level ground.
FG015915
Figure 7
3. Move safety lever to "LOCK" position.
Unlock
Lock EX1300566
Figure 8
4. Allow engine to run at low idle for a minimum of five

minutes to allow engine to cool. If this is not done, heat
surge can occur.
HAOB290L
Figure 9

4-4
5. Stop engine by turning key to "O" (OFF) position. Remove
key from starter switch. O I
WARNING
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.
Figure 10
6. Before starting maintenance work, hang up a tag, "Do Not

Touch When Performing Inspection or Maintenance" on
cabin door or work lever.
FG015938
Figure 11

4-5
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.
Ambient Temperature
Reservoir Kind of Fluid -58 -40 -22 -4 14 32 50 68 86 104 122 °F
-50 -40 -30 -20 -10 0 10 20 30 40 50 °C
2) SAE 5W-40
SAE 10W-30
Engine Oil 5)
Engine Oil
Pan
3)
SAE 10W-40
4)
SAE 15W-40
Swing Drive SAE 90 and API GL5

Case
Gear Oil 1)
SAE 80W-90 and API GL5
Final Drive
SAE 140 and API GL5
Case
ISO VG. 15
ISO VG. 32
Hydraulic Oil 6)
Hydraulic Oil
Tank
ISO VG. 46
ISO VG. 68
1) ASTM D975 No. 2

Fuel Tank Diesel Fuel
ASTM D975 No. 1

4-6
Grease Fitting Grease 1) Multipurpose Lithium Grease NLGI No. 2
Cooling Add Antifreeze

Coolant 1)
System (50% antifreeze - 50% distilled water)
1)
Installed at factory.
2)
(5W40) - Recommended for use at extremely low temperature below -20°C.
3)
(10W40) - Filled at factory. Doosan genuine engine oil is recommended for use.
4)
(15W40) - Doosan genuine engine oil is recommended for use.
5)
(Engine oil) - Engine oil must meet API CI-4/ACEA E5.
6)
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.
API: American Petroleum Institute.
ACEA: Association des Constructeurs Europens d'Automobiles.
ASTM: American Society of Testing and Materials.
ISO: International Organization for Standardization.
NLGI: National Lubricating Grease Institute.
SAE: Society of Automotive Engineers.
IMPORTANT
Do not mix oils from different manufacturers. DOOSAN
does not endorse specific brands but recommends that
owners select quality oils whose manufacturers provide
assurance that required standards will always be met or
exceeded.
IMPORTANT
Fluctuating daily or weekly extremes of temperature, or
operation in subzero freezing temperatures, may make it
impractical to use straight weight lubricants. Select
lubricants that are appropriate for climate conditions.

4-7
Coolant and Water for Dilution
• The coolant has the important function of preventing
corrosion and preventing freezing.
Even in areas where freezing is not an issue, use of
antifreeze coolant is essential.
DOOSAN machines are supplied with DOOSAN coolant.
DOOSAN coolant has excellent anticorrosion, antifreeze
and cooling properties and can be used continuously for
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.
• When diluting antifreeze coolant, use distilled water.
Natural water, such as a river water or well water (hard
water), contains large amounts of minerals (calcium,
magnesium, etc.), and this makes it easier for scale to form
inside engine or radiator. Once scale is deposited inside
engine or radiator, it is extremely difficult to remove.
If tap water needs to be used, refer to "Engine Cooling
System" on page 4-71 for further information on standards
and precautions.
• When using antifreeze, always observe precautions given
in this manual.
• Antifreeze coolant is flammable, so be sure to keep it away
from any flame.
• The ratio of DOOSAN coolant to water differs according to
ambient temperature.
For details of ratio when mixing, see "Antifreeze
Concentration Tables" on page 4-73.
DOOSAN coolant may be supplied premixed. Never add
distilled water.
• If engine overheats, wait for engine to cool before adding
coolant.
• If coolant level is low, it will cause overheating and
corrosion problems because of air entering coolant.
• Never mix lime (hard water), salt or water contained metal
material with coolant.

4-8
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. gal.)
4 liters
Travel Reduction Gear (Each)
(1.05 U.S. gal.)
5 liters
Swing Reduction Gear
(1.3 U.S. gal.)
NOTE: If the level is between lower limit line and upper limit
line of the gauge, the level is correct.
If the level is low, open the cover on the tank and add
hydraulic oil.

4-9
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
Engine Oil Filter Air Conditioner Filter
Hydraulic Oil Drain Water
Hydraulic Oil Return Filter Fuel Cap Filter
Hydraulic Oil Tank Breather

4-10
Description of Lubrication and Service Chart
13 19 20 21 4 5 6 3 10
1
18
17 15
16
2
14
12
2
11
10h
50h
250h
500h
1000h
2000h
8 22 7 1
EX1300918
Figure 12

4-11
SERVICE DATA
Service Interval
No. Items to Check Service Qty.
10 50 250 500 1000 2000
1 Arm, Bucket Joint Pin Grease 6 F100 W10
2 Boom, Arm Joint Pin Grease 11 F100 W10
3 Swing Bearing Grease 2 W10
4 Pinion Gear (Swing) Grease 1
5 Swing Reduction Gear Grease 1 W10
6 Swing Reduction Gear Gear Oil 5ℓ V F
7 Track Spring Grease 2 W10
8 Travel Reduction Gear Gear Oil 2 x 4ℓ F, V
9 Engine Oil Engine Oil 27ℓ V
10 Hydraulic Oil Tank** Hydraulic Oil 130ℓ V
11 Fuel Tank Diesel 320ℓ V
Water Separator & Pre
12 Cartridge 1 D, V
Fuel Filter (Fuel Prefilter)
13 Radiator Coolant 30ℓ V
14 Hydraulic Oil Return Filter Element 1 F
15 Pilot Filter Element 1 F
Hydraulic Oil Suction
16 Strainer 1 C
Strainer
17 Engine Oil Filter Cartridge 1 F
18 Main Fuel Filter Cartridge 1
Air Cleaner (Outer) Element 1 C
19
Air Cleaner (Inner) Element 1
Air Conditioner Filter
Cartridge 1 C
(Outer)
20
Air Conditioner Filter
Cartridge 1 C
(Inner)
21 Air Breather Filter* Element 1
22 Fuel Cap Filter Element 1
V: Maintenance and Refill.
C: Cleaning.
D: Drain Water.
F: First Time Exchange Only.
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.
: Replacement On Every Interval.
NOTE: For additional service items see list of "Maintenance Intervals" on page 4-13.
*: When the machine is operated under dusty work sites, the air breather filter needs to be cleaned or replaced
on a regular basis even before the expected replacement date.
**: If DOOSAN Genuine Oil used, hydraulic oil change interval is 4,000 hours.
4,000 oph or 2 years - make hydraulic oil sampling 2,000 oph or 1 year, change if need.

4-12
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
Check for Leaks in Fuel System 4-18
Check Water Separator & Pre Fuel Filter (Fuel Prefilter) and Drain Water as Required 4-19
Check Oil Level of Swing Reduction Device 4-20
Clean Dust Net in Front of Oil Cooler and Intercooler 4-21
Check Cooling System and Refill as Required 4-21
Check Level of Window Washer Liquid 4-22
Inspect Bucket Teeth and Side Cutters for Signs of Wear 4-22
Inspect Cooling Fan Blade 4-23
Check Air Intake System 4-23
Inspect Seat Belt for Proper Operation 4-23
Inspect Structure for Cracks and Faulty Welds 4-24
Check Operation of All Switches 4-24
Check the Operation of Pilot Cutoff Switch 4-24
Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor
4-25
Lights
Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-up and at Normal
4-26
Operating Temperature. Listen for Any Abnormal Sounds
Check Operation of All Controls 4-26
50 Hour / Weekly Service
Perform All Daily Service Checks 4-27
Grease Arm and Front Attachment Pins 4-27
Grease Swing Bearing 4-28
Drain Water and Sediment from Fuel Tank 4-29
Check Engine Fan Belt for Cracks, Wear and Correct Tension (After First 50 Hours) 4-29
Inspect Track Assemblies for Proper Tension and Loose, Worn or Damaged Parts (Links,
4-29
Shoes, Rollers, Idlers)
250 Hour / Monthly Service
Perform All Daily and 50 Hour Service Checks 4-30
Grease Arm and Front Attachment Pins 4-30
Check Engine Fan Belt Tension 4-32
Check Engine Fan Belt Wear 4-33
Change Breaker Filter (Optional) 4-34
Replace Hydraulic Oil Return Filter (After First 250 Hours) 4-35
Change Pilot Filter (After First 250 Hours) 4-35
Inspect Pins and Bushings of Front End Attachments for Signs of Wear 4-35
Check Fluid Levels in Batteries 4-35
Inspect for Any Loose or Missing Nuts and Bolts 4-35

4-13
SERVICE ITEM PAGE
Inspect Fuel System Hose Clamps 4-35
500 Hour / 3 Month Service
Perform All Daily, 50 and 250 Hour Service Checks 4-36
Grease Swing Gear and Pinion 4-36
Change Engine Oil and Filter 4-37
Clean Air-Conditioning Outer Filter 4-38
Check and Clean Air-Conditioning Inner Filter 4-39
Clean Radiator, Oil Cooler, Intercooler, Fuel Cooler and Air Conditioner Condenser Core 4-40
Clean Outer Filter of Air Cleaner 4-41
Change of Water Separator & Pre Fuel Filter (Fuel Prefilter) 4-43
Change Main Fuel Filter 4-44
Check Oil Level in Travel Reduction Device (One on Each Side of Unit) 4-45
Change Oil in Travel Reduction Device (One on Each Side of Unit) (After First 500 Hours) 4-45
Change Swing Reduction Device Oil (Drain and Refill After First 500 Hours) 4-45
1,000 Hour / 6 Month Service
Perform All Daily, 50, 250 and 500 Hour Service Checks 4-46
Grease Swing Reduction Device 4-46
Change Air Breather Filter 4-46
Replace Hydraulic Oil Return Filter 4-47
Change Pilot Filter 4-48
Change Oil in Travel Reduction Device (One on Each Side of Unit) 4-49
Change Swing Reduction Device Oil 4-50
Change Air-Conditioning Outer Filter 4-51
Change Air-Conditioning Inner Filter 4-52
Check Air Conditioner Refrigerant 4-53
Change Fuel Cap Filter 4-54
Check and Adjust Engine ** 4-55
2,000 Hour / Yearly Service
Perform All Daily, 50, 250, 500 and 1,000 Hour Service Checks 4-56
Replace Outer and Inner Air Cleaner Elements 4-56
Change Radiator Coolant 4-57
Hydraulic Oil Exchange and Suction Strainer Cleaning 4-59
Check Alternator and Starter** 4-61
Check All Rubber Antivibration Shock Mounts 4-61
Perform and Record Results of Cycle Time Tests 4-61
Inspect Machine to Check for Cracked or Broken Welds or other Structural Damage 4-61
Check, Adjust Valve Clearance ** 4-61
Check Head Bolt Torques 4-61
4,000 Hour / Biennial Service
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.

4-14
10 HOUR / DAILY SERVICE
Grease Boom, Arm and Front Attachment

Pins (for first 100 hours)
WARNING
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. Figure 13
Be careful to any kinds of works for nipples and hydraulic
line plugs.
Grease every 10 hours for first 100 hours and every 50 or 250
hours thereafter (See page 4-27).
NOTE: If the unit has been running or working in water the
front attachment must be greased on a 10 hour/daily
basis.
Check Engine Oil Level

2
1
WARNING
Allow the engine to cool before checking the oil level to
avoid burns by touching hot engine parts.
NOTE: When checking level using a dipstick always remove

and wipe it clean before making final level check.
1. Stop engine and wait for fifteen minutes. This will allow all
FG006441
oil to drain back to oil pan.
Figure 14
2. Remove dipstick (1, Figure 14) and wipe the oil off with a
clean cloth.
3. Insert dipstick fully in the oil gauge tube, then take it out
again.

4-15
4. Engine oil level must be between "HIGH" and "LOW"
marks on dipstick. H
NOTE: If oil is above "HIGH" mark on dipstick, some

must be drained to return oil to proper level. L
5. Add oil through engine oil fill cap (2, Figure 14), if the oil
level is below the "LOW" mark.
FG000616
Figure 15
Check Level of Hydraulic Oil Tank
WARNING
The hydraulic oil will be hot after normal machine
operation. Allow the system to cool before attempting to
service any of the hydraulic components.
ARO1760L
The hydraulic tank is pressurized. Turn the breather cap
Figure 16
slowly to allow the pressurized air to vent. After the
pressure has been released, it is safe to remove either the
fill cap or service covers.
1. Park machine on firm and level ground. Lower boom and

position bucket on ground as shown in Figure 17.
2. Move engine speed to "LOW IDLE".
EX1300562
Figure 17

4-16
4. Check level gauge through right glass of cabin. Oil level
must be between marks on sight gauge.
H
L
FG015941
Figure 18
5. If the level is below "L" mark add oil.

A. Stop engine.
B. The hydraulic tank is pressurized. Lift the breather
cap slowly to allow the pressurized air to vent.
C. Remove the upper cover of the hydraulic tank and
add oil.
IMPORTANT
FG015942
Figure 19
Do not fill above "H" mark on sight gauge. Overfilling
can result in damage to equipment and oil leaking
from hydraulic tank because of expansion.
6. If oil level is above the "H" mark drain oil.

A. Stop engine and wait for the hydraulic oil to cool
down.
B. Drain the excess oil from drain plug (Figure 20) at the
bottom of the tank into a suitable container, using a
hose connected to the valve.
NOTE: Dispose of drained fluids in compliance with all
applicable environmental laws and regulations.
FG015943
Figure 20
Check for Leaks in Hydraulic System

1. Perform a daily walk-around inspection to make sure that
hoses, piping, fittings, cylinders and hydraulic motors are
not showing any signs of leakage. If any is noted,
determine the source of the leak and repair.

4-17
Check Fuel Level
1
WARNING
Use extreme safety precautions while refueling to prevent
explosions or fire. 2
Immediately clean up any split fuel.
FG015944
1. At end of each work day, fill fuel tank. Add fuel through fuel
Figure 21
fill tube (1, Figure 21). When working at a temperature of
0°C (32°F) or higher, use ASTM No. 2-D or its equivalent.
At temperatures below 0°C (32°F) use ASTM No. 1-D or its
equivalent.
2. Make sure that fuel fill hose is grounded to the excavator
before fueling begins.
3. Check the amount of fuel in the tank by observing the fuel
tank sight gauge (2, Figure 21).
NOTE: See "Fluid Capacities" on page 4-9 for capacity.
4. The excavator may be equipped with the optional battery
operated fuel fill pump. The pump assembly is in the
hydraulic pump compartment. Put the suction hose of the
pump into the fuel resupply tank. Turn the switch in the
pump compartment "ON", and the fuel will be pumped into
the excavator fuel tank.
NOTE: See "Fuel Transfer Pump (Optional)" on
page 4-74, for further information.
5. Do not overfill the tank.
6. Securely tighten cap after fueling.
NOTE: If breather holes (3, Figure 22) in cap are
clogged, a vacuum may form in the tank
preventing proper fuel flow to engine. Keep 3
holes in fuel cap clean.
FG000317
Figure 22
Check for Leaks in Fuel System

1. Perform an inspection of the engine compartment to verify
that fuel system is not leaking. If any is noted, determine
the source of the leak and repair.

4-18
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
1. A fuel prefilter is inside the right rear side access door.

2. Open the access door on right rear side of the machine.
FG014421
Figure 24
3. It is necessary to drain the collected water if the bowl is full

of water or sediment.
4. Position a small container under fuel prefilter. Drain water
or sediment by opening drain valve (2, Figure 25) on
bottom of bowl (1).
1
applicable environmental laws and regulations. 2
5. Close drain valve.

open close
FG000438
Figure 25

4-19
Check Oil Level of Swing Reduction
Device
WARNING
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.
NOTE: When checking level using a dipstick always remove

2
and wipe it clean before making final level check.
1
1. Remove dipstick (1, Figure 26) and wipe the oil from the
dipstick with a cloth.
2. Insert dipstick (1, Figure 26) fully into dipstick tube.
FG015945
Figure 26
3. When dipstick is pulled out, oil level must be between

"HIGH" and "LOW" marks on dipstick.
NOTE: If oil is above "HIGH" mark on dipstick, some H
must be drained to proper level.
4. If the oil does not reach the "L" mark on the dipstick, add oil L
through fill port (2, Figure 26).
FG000419
Figure 27
5. If the oil level exceeds the "H" mark on the dipstick, open
cap (3, Figure 28) of drain valve and connect hose (4) to 3
the valve. Drain the excessive oil into a suitable container.
FG015946
Figure 28

4-20
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
If using compressed air or water to clean the dust net, make
sure that proper eye protection is worn.
1. Loosen the wing bolt(s) and remove dust net.

2. Clean with compressed air or water.
Check Cooling System and Refill as Required
WARNING
Allow the engine to cool before releasing the radiator cap.
Make sure to loosen the cap slowly to release any
remaining pressure.
Radiator cleaning is performed while the engine is running.
Take extreme caution when working on or near a running
engine. Make sure to lock out and tag the controls notifying
personnel that service work is being performed.
Do not remove radiator cap unless it is required. Observe
the coolant level in the coolant recovery tank.
NOTE: Do not mix ethylene glycol and propylene glycol

antifreeze together.
1. When the engine is cold, remove the radiator cap and
check the coolant level inside the radiator. Do not rely on
the level of coolant in the coolant recovery tank. Refill
radiator as required. Refer to coolant concentration table.
(See page 4-73)
2. Check to make sure that the coolant transfer line from the
coolant recovery tank to the radiator is free and clear of
obstructions, or not pinched.
3. Observe the level of coolant in the coolant recovery tank.
The normal cold engine fluid level must be between
"FULL" and "LOW" marks on tank.
FG015972
4. If the coolant is below the "LOW" mark, add genuine part of Figure 30
50% concentration coolant to the tank.

4-21
NOTE: When refill or replace coolant, select "heater-full
hot" mode to fully open the water valve.
Coolant will then flow into the heater's core to
prevent air from being trapped in it.
EX1502246
Figure 31
Check Level of Window Washer Liquid

1. Open left rear access door and check fluid level in
windshield washer tank.
2. Open fill cap and add fluid.
NOTE: Use a washer liquid that is rated for all seasons.
This will prevent freezing during cold weather
operation.
FG015973
Figure 32
Inspect Bucket Teeth and Side Cutters for

Signs of Wear
1. On a daily basis, inspect the bucket teeth to make sure that
tooth wear or breakage has not developed.
2. Do not allow the replaceable bucket teeth to wear down to
the point that the bucket adapter is exposed. See Figure
33.
NOTE: These instructions are only for DOOSAN OEM
buckets. If you are using other manufacturers'
buckets, refer to their specific instructions. Figure 33
Reference
Description
Number
1 Point
2 Adapter
3 Pin

4-22
Inspect Cooling Fan Blade
WARNING
Personal injury can result from a fan blade failure. Never
pull or pry on the fan. This can damage the fan blade(s) and
cause fan failure.
1. An inspection of the cooling fan is required daily. Check for Figure 34

cracks, loose bolts, bent or loose blades, and for contact
between the blade tips and the fan shroud. Check the fan
to make sure it is securely mounted. Tighten the bolts if
necessary. Replace any fan that is damage.
Check Air Intake System
CAUTION
AVOID INJURY
Hot engine components can cause burns.
Avoid contact with hot engine components
HAOA050L
1. Park the machine on a level surface, lower the attachment
Figure 35
to the ground, move safety lever to "LOCK" position, and
stop engine.
2. Check the engine intake hose, and hose bands for damage
and tightness.
3. 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
Do not operate engine if any leaks or defects are found Figure 36
on air intake system.
Inspect Seat Belt for Proper Operation

See "Seat Belt" on page 1-34 for further information.

4-23
Inspect Structure for Cracks and Faulty
Welds
1. During the daily walk-around inspection and when
greasing the machine, look for any visible damage to the
machine. Repair or replace any damaged parts before
operating the machine.
Check Operation of All Switches

1. Verify the working condition of all switches before starting
the engine.
Check the Operation of Pilot Cutoff Switch

A pilot cutoff switch has a pivoting safety lever that deactivates
the work group, swing and travel control functions.
When the safety lever is moved down into "LOCK" position, the
work group, swing and travel control functions are deactivated.
Unlock
When the safety lever is moved up into "UNLOCK" position, the
work group, swing and travel control functions can be operated.
Lock EX1300566
WARNING Figure 37

The PILOT CUTOFF SWITCH (safety lever) must deactivate
the work group, swing and travel control functions when
the safety lever is moved down into "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

1. Check for and keep bystanders away from the work area.
Sit in operator's seat and fasten seat belt.
2. Start engine and move safety lever up into "UNLOCK"
position.
3. Operate the work group (joystick) levers in all directions to
check that the boom, arm, bucket (or other attachment)
and swing functions operate correctly. Also, check that the
travel controls operate properly.
NOTE: Hydraulic system must be warmed up to
operating temperatures.
4. Raise the boom and arm so the bucket (or other
attachment) is about 1 m (3 ft.) off the ground.
5. Move the safety lever down into "LOCK" position to
deactivate the work group and travel functions. Move the
work group (joystick) levers. There must be no movement

4-24
of the boom, arm, and attachment or swing functions when
the controls are moved.
6. With the safety lever still in the "LOCK" position, move the
travel controls. There must be no movement of the
excavator tracks.
7. Move safety lever up into "UNLOCK" position. Raise the
boom so the bucket (or other attachment) is about 3 m
(10 ft.) off the ground. Operate the work group (joystick)
lever to lower the boom slowly. While boom is lowering,
move the safety lever down into "LOCK" position. Boom
movement must stop. Repeat these steps for arm, bucket
(attachment), swing and travel functions.
8. Lower work group to the ground and stop engine.
NOTE: If the PILOT CUTOFF SWITCH (safety lever) does
not deactivate the work group and travel functions as
described above or if any parts are damaged, bent or
missing, contact your DOOSAN distributor
immediately for service. DO NOT MODIFY THE
SYSTEM.
Check Operation of All Exterior Lights,

Horn and Control Console Indicator
and Monitor Lights
1. Turn engine starter switch to "I" (ON) position and observe
all of the indicator lights.
2. Restore operation of any light bulbs that do not turn "ON"
at this time.
3. Sound the horn. Repair or replace if required.
4. Turn "ON" and inspect all exterior work lights. Replace any
monitors, burned out bulbs or cracked or broken housings
or lenses.

4-25
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. Follow all warm up instructions listed in the
Operating Instruction section of this manual. Make sure to
cycle oil through all of the components, including all
cylinders, both travel motors and the swing motor. Cold
hydraulic oil in the lines and components needs to be
warmed before beginning full operation. If this is not done,
damage to the cylinders or hydraulic motors can occur.
1. With the engine at rated speed, operate all of the controls.

2. Follow cold weather hydraulic system warm-up
procedures.
3. Note any slow operations or unusual movements.
Determine the cause and repair the fault before operating.

4-26
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.
basis.
• Position machine as shown below and lower the front
attachment to the ground and stop engine.
• Press the grease fitting and inject grease with the grease
gun on the marked point
• After injection, clean off the old grease that has been
purged.
D B, E C A
FG015974
Figure 38
Reference Reference
Number Number
A Arm Link Joint Pin (1 Point) D Bucket Link Joint Pin (1 Point)
B Link Joint Pin (2 Points) Bucket Cylinder Rod Pin
E
C Arm Bucket Joint Pin (1 Point) (1 Point)

4-27
A. Arm link joint pin (1 point)
B
B. Link joint pin (2 points) B
C. Arm bucket joint pin (1 point)
D. Bucket link joint pin (1 point) A
D
FG009561
Figure 39
E. Bucket cylinder rod pin (1 point)
FG000142-1
Figure 40
Grease Swing Bearing

1. Park machine on firm and level ground. Lower the front
2. There are three grease fittings for the swing bearing. Do
not over lubricate. Purge old grease with new. Remove all
purged grease.
FG015975
Figure 41

4-28
Drain Water and Sediment from Fuel Tank
1. Perform this procedure before operating the machine.
2. 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. FG015976
Figure 42
FG015977
Figure 43
Check Engine Fan Belt for Cracks, Wear and

Correct Tension (After First 50 Hours)
1. Inspect after first 50 hours of operation and every 250
hours thereafter. For details, See "Check Engine Fan Belt
Tension" on page 4-32.
Inspect Track Assemblies for Proper

Tension and Loose, Worn or Damaged
Parts (Links, Shoes, Rollers, Idlers)
1. Do a daily walk-around inspection of all components
including the track assemblies. Look for missing, damaged
or excessively worn parts. See "Track Tension" on
page 4-78.
2. Jack up each track and perform the two speed travel motor
test.

4-29
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.
basis.
• Position machine as shown below and lower the front
• Press the grease fitting and inject grease with the grease
gun on the marked point
• After injection, clean off the old grease that has been
purged.
B, C, D
E
F
A G FG015979
Figure 44
Reference Reference
Number Number
Boom Cylinder Head Pin E Boom Arm Joint Pin (2 Points)
A
(2 Points) F Arm Cylinder Rod Pin (1 Point)
B Boom Foot Pin (2 Points) Bucket Cylinder Head Pin
G
C Boom Cylinder Rod Pin (2 Points) (1 Point)
D Arm Cylinder Head Pin (1 Point)

4-30
A. Boom cylinder head pin (2 points)
A A
FG001389
Figure 45
B. Boom foot pin (2 points)

C. Boom cylinder rod pin (2 points)
C
D. Arm cylinder head pin (1 point)
D
C
B
FG015980
Figure 46
E. Boom arm joint pin (2 points)

F. Arm cylinder rod pin (1 point) E
G. Bucket cylinder head pin (1 point) E
FG001391
Figure 47

4-31
Check Engine Fan Belt Tension 10 mm/10 kg Fan
Alternator
IMPORTANT
A loose fan belt can cause engine overheating, poor
charging, and/or premature belt wear. A belt that is too tight
can cause damage to the water pump, alternator bearing or Compressor
belt.
Crankshaft FG015981
1. Inspect every 250 hours. (Inspect after first 50 hours of Figure 48
operation.)
2. With the engine shut off, check the tension of the fan belt
by pressing downwards on the belt, midway between the
fan pulley and alternator pulley. The belt should flex
approximately 10 mm (0.4 in). See Figure 48. To adjust the
belt, loosen the alternator adjustment plate bolts, adjust the
belt tension and retighten the bolts.

4-32
Check Engine Fan Belt Wear
WARNING
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
When checking, adjusting or replacing drive belts, care
must be taken to prevent accidental cranking of the engine.
Be sure the starter switch is in the "OFF" position and the
controls are tagged.
1. Replace badly worn, greasy or severely cracked belts

immediately. These conditions prevent proper belt
function. Visually inspect the belt. Check the belt for
intersecting cracks. Transverse (across the belt width)
cracks are acceptable. Longitudinal (direction of belt
length) cracks that intersect with transverse cracks are not
acceptable. Replace the belt if it is frayed or has pieces of
material missing.
2. Before installing new belts, make sure all pulley grooves
are clean and not worn. Replace pulley, if damaged, or if
the grooves are worn.
3. All pulley support bearings, shafts, and brackets must be in
working order.
4. When replacing belts and pulleys, pulley alignment must
be checked with belts tensioned and brackets securely
clamped. A misalignment that can be detected by the eye
is detrimental to belt performance.
5. Do not force the belts into the pulley grooves by prying with
a screwdriver or pry bar. This will damage the belt side
cords which will cause the belts to turn and result in
complete destruction of the belts in operation.
6. Belts on new machines and replacement belts lose their
tension as they seat into the pulley grooves. Check the
tension of new belts at 50 hour intervals until tension is
stabilized and thereafter, every 250 hours. If the tension
falls below the required minimum, the belt slips damaging
the belts and pulley grooves.
NOTE: When operating in abrasive conditions, check
tension every 100 hours.

4-33
Change Breaker Filter (Optional)
WARNING
operation.
Allow the system to cool down before changing pilot filter.

2. Loosen the hydraulic oil tank breather cap to release FG015982
pressure. Figure 50
3. Locate breaker filter assembly (Figure 50).
4. Position a container under the filter assembly. Remove
drain plug and completely drain the assembly.
5. Using a 30 mm spanner, unscrew filter housing from filter
bottom.
6. Remove O-ring from filter head.
7. Replace filter.
8. Apply a small amount of oil around the entire O-ring and
install the filter housing on the filter head.
NOTE: Tightening torque: 27 kg•m (265 Nm, 195 ft lb)
9. Install drain plug in bottom of filter housing.
10. After changing breaker filter, vent air from pump and check
level of hydraulic oil tank.

4-34
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).
Inspect Pins and Bushings of Front End

Attachments for Signs of Wear
Check Fluid Levels in Batteries

See "Inspection of Battery Electrolyte Level" on page 4-68 for
further information.
Inspect for Any Loose or Missing Nuts and

Bolts
Inspect Fuel System Hose Clamps

4-35
500 HOUR / 3 MONTH SERVICE
Perform All Daily, 50 and 250 Hour Service

Checks
Grease Swing Gear and Pinion
WARNING
Greasing swing gear and pinion must be serviced by only
one person.
1. Remove inspection cover and inspect the condition of the

grease. Make sure that water or other contaminants are
not noticeable.
NOTE: The upper structure must be rotated a little at a
time so the entire face of the swing gear can be
lubricated. Use extreme caution when
performing this operation.
FG015983
Figure 51
2. If water or other contaminations are found, remove lower

access cover so the gear teeth can be thoroughly cleaned
and lubricated.
3. Install access covers after lubricating gear teeth.
FG009571
Figure 52

4-36
Change Engine Oil and Filter
NOTE: Change engine oil and filter after first 50 hours of
operation or rebuild, then every 500 thereafter.
WARNING
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.
1. Position a larger container under the engine. Remove cap

(1, Figure 53) and install hose (2) to drain the engine oil.
Remove hose (2) and install cap (1).
1
FG000144
Figure 53
2. Replace engine oil filter by using filter wrench. The engine

oil filter is a spin-on type. See Figure 54. Remove and
discard filter.
3. Install new filter. Apply a small amount of oil around filter
gasket. Screw filter on head until gasket contacts head,
turn filter 1/2 turn more.
FG015984
Figure 54
4. Refill the engine with the correct oil through the oil fill port
(Figure 55). Refer to the Lubrication Table of this manual
for the recommended oil for the operating conditions.
5. Start engine. Run engine for five minutes at "LOW IDLE",
and check engine oil pressure light.
6. Stop engine. Look for signs of leaks at filter. Recheck oil
level after fifteen minutes.
FG005870
Figure 55

4-37
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. If filter is damaged, replace
damaged filter with a new one.
WARNING
All service and inspection of air-conditioning system must
be performed with the starter switch in the "O" (OFF)
position.
WARNING
If using compressed air to clean the element, make sure
that proper eye protection is worn.
NOTE: All right and left call outs are based on the operator
being seated in the operator's seat facing the front. 1
1. The outer filter is located behind the operator’s seat (1,
Figure 56).
FG016060
Figure 56
2. Open the cover by removing knobs (2, Figure 57).

2
2
FG016061
Figure 57

4-38
3. Remove filter (3, Figure 58) and inspect for any damage.
4. Use compressed air to clean filter. If filter is still dirty, then 3
change to new one.
5. Reassemble filter and cover in reverse order.
FG016062
Figure 58
Check and Clean Air-Conditioning Inner

Filter
WARNING
be performed with the starter switch in the "O" (OFF) 1 FG015051
position.
Figure 59
WARNING
If using compressed air to clean the element, make sure
that proper eye protection is worn.

2. Remove the screw (2, Figure 60) and filter (3, Figure 60)
from the cover.
3. Use compressed air for cleaning filter.
If the filter is damaged, replace it by new one.
If the filter is very dirty use a mild soap or detergent and
water to clean it.
3
4. Reassemble filter in reverse order. 2
FG015052
IMPORTANT Figure 60
If water was used to clean filter, be certain it is

completely dry before installing.

4-39
Clean Radiator, Oil Cooler, Intercooler,
Fuel Cooler and Air Conditioner
Condenser Core
WARNING
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.
FG015985
Figure 61
1. Open the rear left door and engine cover.

2. Loosen the wing bolt(s) and remove dust net from in front
of oil cooler and intercooler.
3. Clean the outside of the radiator and oil cooler, intercooler
and fuel cooler with compressed air, steam or water. Wash
from the outside of the engine compartment inwards.
Repeat the cleaning process from the inside of the engine
compartment outwards to remove all dirt and debris.
NOTE: Clean dust net and install it after cleaning
radiator, oil cooler, intercooler and fuel cooler.
FG015986
4. Clean air conditioner condenser core with compressed air,
steam or water. Figure 62
IMPORTANT
To prevent damage to the cores, apply compressed air
from an appropriated distance. Damaged core can
cause water leakage or overheating. In a dusty site,
check the core daily, irrespective of the maintenance
interval.

4-40
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
PWR
service interval must be shortened.
FG013734
Figure 63
WARNING
Never clean or attempt to remove the air cleaner filter if the
engine is running.
If using compressed air to clean the filter, make sure that
proper eye protection is worn.
1. Locate the air cleaner assembly.

NOTE: When it reaches every 500 hours or If indicator
light (Figure 63) on instrument panel comes
"ON" the air cleaner must be serviced.
NOTE: Replace outer filter after cleaning 5 times or
every 2,000 hours/1 year of service.
2. Remove and clean rubber evacuator valve (1, Figure 64)
from bottom of air cleaner housing cover (2). Inspect seal
lips for wear or damage. Replace valve if necessary.
FG015987
NOTE: Install evacuator valve with lips parallel to the
Figure 64
cover.
3. Remove the access cover (2, Figure 65) by loosening the

latches (3).
4. Remove outer filter (4, Figure 65) from the housing. Do not
5
remove inner filter (5).
4
3
1 FG000702
Figure 65

4-41
5. 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
6. 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.
7. Clean the inside of the air cleaner body and the inside of
the air cleaner cover. Do not use compressed air.
8. Properly install the air filter and cover.
9. After filter service be sure to install cover with arrows
pointing "UP".
NOTE: If after cleaning the outer filter, the air cleaner FG000412
clogged indicator remains "ON", replace the
Figure 67
outer and inner filters. Do not clean inner filter.

4-42
Change of Water Separator & Pre Fuel
Filter (Fuel Prefilter)
1. Open the right rear side door to access fuel prefilter.
2. Position a small container under prefilter. Drain fuel by
opening drain valve on bottom of filter.
FG014434
Figure 68
3. Remove bowl using supplied tool.

4. Remove cartridge.
FG005878
Figure 69
5. Coat surface of packing (2, Figure 70) with fuel on new

cartridge (1).
6. Tighten the cartridge by hand until the packing comes into
contact with the surface of the filter housing head.
7. When it reach the surface, tighten the cartridge about 3/4 2
of a turn more.
8. Coat surface of seal (3, Figure 70) with fuel, and tighten
the bowl with tool.
1
FG000428
Figure 70

4-43
Change Main Fuel Filter
WARNING
Exchange filter after waiting for engine to cool. Be careful of
fire hazards. Do not smoke.
1. Access fuel filter through right side door. FG005879

Figure 71
2. Position a small container under fuel filter.
3. Unscrew fuel filter from head assembly. Discard fuel filter.
4. After cleaning filter head, install new fuel filter. Screw filter
on head until gasket contacts head, and turn filter 1/2 turn
more with a filter wrench.
NOTE: Coat fuel filter gasket with fuel.
NOTE: Fill fuel filter with clean fuel. This will help
reduce fuel system priming. FG000478
Figure 72
Fuel System Priming

1
If air remains in the fuel inlet line to the engine, it can cause the
engine to run in an abnormal condition. Air may impact the 2
starting capability of the engine, and may also result in surging
engine speeds.
If the machine happens to have run out of fuel, or if the fuel filter
has been replaced, air may need to be bleed using the following
procedure:
1. Stop engine.
FG000431
2. Loosen plug (1, Figure 73) on the fuel prefilter head.
Figure 73
3. Pump the hand operated primer pump (2, Figure 73) on the
fuel prefilter. Pump primer until fuel is present at plug hole
in fuel prefilter head.
4. Tighten plug (1, Figure 73) in fuel prefilter head.
5. Continue to pump primer pump until a strong resistance is
felt.
6. Start engine and look for signs of leaks.
7. Repeat procedure if necessary.

4-44
Check Oil Level in Travel Reduction
Device (One on Each Side of Unit)
3
WARNING 1

FG028838
Before removing the motor case, loosen the plug slightly to Figure 74
allow pressurized air to escape. Residual pressure in the
travel reduction device can cause the plug to be dislodged
and oil to squirt out suddenly.
Reference
Description
Number
1 Oil Level Plug
2 Drain Plug
3 Fill Plug
1. Make sure that the machine is on firm and level ground.

2. Rotate the track until ports (1 thru 3, Figure 74) are in their
proper positions as shown.
3. Loosen fill plug (3, Figure 74) slightly to allow pressurized
air to escape.
4. Remove oil level plug (1, Figure 74).
5. Check oil level. The oil must be near the bottom of the level
plug opening.
6. Add oil through the fill plug (3, Figure 74) opening, if
necessary.
7. Clean and install oil level and fill plugs (1 and 3, Figure 74).
8. Repeat this procedure on the other travel reduction device.
Change Oil in Travel Reduction Device

(One on Each Side of Unit) (After First
500 Hours)
NOTE: Drain and refill oil after first 500 hours of operation or
rebuild, and every 1,000 hours thereafter (See page 4-49).
Change Swing Reduction Device Oil (Drain

and Refill After First 500 Hours)
NOTE: Change swing reduction device oil after first 500
hours on a new machine and every 1,000 hours
thereafter (See page 4-50).

4-45
1,000 HOUR / 6 MONTH SERVICE
Perform All Daily, 50, 250 and 500 Hour

Service Checks
Grease Swing Reduction Device

2. Remove air vent plug (1, Figure 75) from swing reduction
device.
FG015988
Figure 75
3. Press grease fitting and inject grease with the grease gun
on the marked point (2, Figure 76).
4. Install air vent plug (1, Figure 75) in swing reduction
device.
2
FG015989
Figure 76
Change Air Breather Filter 1

2
2. Lift the breather cap(2. Figure 77) slightly to release the
internal pressure.
3. Unscrew the bolt (1, Figure 77) and take off the breather
3
cap (2, Figure 77).
4. Change a filter cartridge (3, Figure 77) and assemble the
breather cap by tighting the bolt.
NOTE: Used filter should always be disposed of
according to local regulations.
NOTE: When the machine is operated under dusty
work sites, the air breather filter needs to be
FG013207
cleaned or replaced on a regular basis even Figure 77
before the expected replacement date.

4-46
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.
FG013832
Figure 78
WARNING 3
The hydraulic oil will be hot after normal machine 1

The hydraulic tank is pressurized. Loosen the hydraulic
breather cap slightly to allow the pressurized air to vent. FG015990
After the pressure has been released, it is safe to remove
Figure 79
either the fill cap or service covers or drain water from the
tank.
IMPORTANT 3 4 6
Make sure to clean any dirt or water from the top of the
7
hydraulic tank, especially around the fill port and filter
ports.
5

8
2. Lift the breather cap (1, Figure 79) slightly to release the
internal pressure.
3. Remove bolts (2, Figure 79) and service cover (3).
Remove spring (4), valve (5) O-ring (6), and bypass
strainer (7), and then filter (8).
4. Remove filter and discard.
according to local regulations. FG000761
5. Install new filter and a new O-ring. Install bypass strainer, Figure 80
valve and spring. Install service cover plate.
6. Tighten the breather cap (1, Figure 79).
7. Run engine for ten minutes at low idle to purge air from circuit.
8. Check level in hydraulic oil tank (See page 4-16). Add oil if
necessary.

4-47
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
operation.
Allow the system to cool down before changing pilot filter.

2. Lift the breather cap (1, Figure 79) slightly to release the
internal pressure.
3. Locate pilot system filter assembly.
4. Unscrew canister (2, Figure 82) and remove O-ring (3) and
filter cartridge (4). 1
NOTE: The canister will be filled with oil. Use caution
when removing this assembly.
3
5. Insert a new filter cartridge and O-ring. Apply a small
amount of oil around the entire O-ring and install the
canister assembly onto the filter head (1, Figure 82). 4

according to local regulations. 2
DS1703795
6. After changing pilot filter, vent air from pump and check
Figure 82
level of hydraulic oil tank.

4-48
Change Oil in Travel Reduction Device
(One on Each Side of Unit)
3
WARNING 1

FG028838
Before removing the motor case, loosen the plug slightly to Figure 83
allow pressurized air to escape. Residual pressure in the
travel reduction device can cause the plug to be dislodged
and oil to squirt out suddenly.
Reference
Description
Number
1 Oil Level Plug
2 Drain Plug
3 Fill Plug
NOTE: Drain oil after first 500 hours of operation or rebuild,

and every 1,000 hours thereafter.
1. Make sure that the machine is on firm and level ground.
2. Rotate the track until ports (1 thru 3, Figure 83) are in their
proper positions as shown.
3. Place a container under drain plug (2, Figure 83) and
remove plugs (1 thru 3) to drain the travel reduction gear
oil.
4. Install drain plug (2, Figure 83). Refill the travel reduction
gear case with fluid through fill port (3) until fluid level is at
port (1). Install level plug (1) and fill plug (3).
5. Repeat this procedure on the other travel reduction device.

4-49
Change Swing Reduction Device Oil 2
NOTE: Change swing reduction device oil after first 500 1
hours of operation or rebuild and every 1,000 hours
thereafter.
WARNING
FG015945
Figure 84
1. Set a container under excavator.

2. Remove cap (3, Figure 85) and install hose (4) to drain the
swing reduction device oil. 3

3. After draining oil, remove hose and install cap.
FG015946
Figure 85
4. Remove breather/fill cap (2, Figure 84) and add oil to "H"
mark on dipstick (1).
FG000419
Figure 86

4-50
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. If filter is damaged, replace
damaged filter with a new one.
WARNING 1

position.
NOTE: All right and left call outs are based on the operator
being seated in the operator's seat facing the front. FG016060
Figure 87
1. The outer filter is located behind the operator’s seat (1,
Figure 87).
2
2
FG016061
Figure 88
3. Remove filter (3, Figure 89) and replace with new one.
4. Reassemble in reverse order. 3
FG016062
Figure 89

4-51
Change Air-Conditioning Inner Filter
WARNING
position.

1 FG015051
2. Remove screw (2, Figure 60) and filter (3, Figure 60) from Figure 90
the cover.
3. Replace it by new one.
4. Reassemble filter in reverse order.
3
2
FG015052
Figure 91

4-52
Check Air Conditioner Refrigerant
WARNING
Mixing of tobacco smoke and freon is deadly.
Do not smoke while servicing or 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.
Inhaling air conditioner refrigerant gas through a lit
cigarette or other smoking method or inhaling fumes
released from a flame contacting air conditioner refrigerant
gas, can cause bodily harm or death.
Use a certified recovery and recycling cart to properly
remove the refrigerant from the air conditioning system.
1. Run engine at about 1,800 rpm. Operate for a minimum of

ten minutes to stabilize the system.
2. Press the "HI" fan speed switch to set maximum air flow.
3. Put the temperature control switch in maximum cooling position.
4. Press the "Internal Air Circulation" switch.
5. Compare the flow of bubbles in the sight glass of receiver
dryer with the drawings in the following table.
IMPORTANT
Overfilling refrigerant can cause dangerous
high-pressure and poor cooling action; and low
refrigerant level can cause compressor damage.
Always maintain refrigerant at normal level.
Amount of
Appearance of the Sight Glass Solutions
Refrigerant
Almost clear.
Normal Any bubbles disappear.
Charge or withdraw the system with

High the correct amount of HFC-134a
No bubbles are seen.
refrigerant.
Low A flow of bubbles is visible.

4-53
Change Fuel Cap Filter
WARNING
External shock or damages to fuel cap may lead to
permanent damage to filter.
FG015720
Figure 93
1. See under the fuel cap as shown on (Figure 94). Rotate

bolt to CCW direction to loosen.
FG015684
Figure 94
2. After disengaging it as shown on (Figure 95), carefully lay it

on floor.
FG015685
Figure 95
3. After disengaging, disengage rubber as shown on (Figure

96).
FG015686
Figure 96

4-54
4. After disengaging as shown on (Figure 96), you may now
exchange it to a new filter as shown on (Figure 97).
FG015687
Figure 97
5. 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.
• Injection Pressure.
• Injection Timing.

4-55
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
PWR
Never clean or attempt to remove the air cleaner element if
the engine is running.
FG013734
Figure 99
NOTE: Replace outer element after cleaning 5 times or every
2,000 hours of service.
NOTE: Replace inner element whenever a new outer
element is installed.
If there is clogged filter signal on the gauge panel, use the
following procedure.
1. Open the access door at the rear of the cabin.
2. Remove the evacuator valve (1, Figure 101) and air
cleaner cover (2).
NOTE: Inspect evacuator valve seal lips for wear or
damage. Replace valve if necessary. Install
FG015987
evacuator valve with lips parallel to the cover.
Figure 100
3. Remove outer filter (4, Figure 101) from the air cleaner
housing.
4. Clean the air cleaner cover and the inside of the air cleaner
2
housing.
5. Remove inner filter (5, Figure 102).
4
1
FG000425
Figure 101

4-56
6. Clean out inside of air cleaner housing. Do not use
compressed air to blow out housing.
7. Install new inner filter. Do not clean and reuse inner
element.
8. Install new outer filter.
9. Install air cleaner cover and evacuator valve. 5
NOTE: Make sure that all gaskets and cover are 4

properly installed and seated.
FG000426
Figure 102
Change Radiator Coolant

NOTE: Do not mix ethylene glycol and propylene glycol
antifreeze together. See "Engine Cooling System" on
page 4-71, for further details.
WARNING
ARO1760L
Allow the engine to cool before releasing the radiator cap.
Figure 103
Make sure to loosen the cap slowly to release any
remaining pressure.
Radiator cleaning is performed while the engine is running.
Take extreme caution when working on or near a running
engine. Make sure to lock out and tag the controls notifying
personnel that service work is being performed.
Do not remove radiator cap unless it is required. Check the
coolant level in the coolant recovery tank.
IMPORTANT
Do not mix up the antifreeze from different makers. Mixing
the two compounds can cause generation of foreign
material which can damage the system. Therefore, it Is
recommended to use 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.
In bitterly cold working conditions, the customer should
frequently check the performance of the coolant for
appropriateness for the weather and then determine change
cycle of the coolant.

4-57
1. Slowly open the radiator cap to allow any pressure to
escape.
2. Place a container under the radiator and open the drain
valve (2, Figure 104).
2
FG001407
Figure 104
3. Remove coolant drain plug (1, Figure 105) from engine.

4. Install drain plug, and close drain valve after coolant has
completely drained from system.
1
5. Fill cooling system with a flushing solution.
6. Run engine at low idle until the coolant temperature gauge
reaches the "BLUE ZONE". Run engine for another ten
minutes.
7. Allow engine to cool.
8. Drain flushing fluid and fill system with water.
9. Run engine again to allow water to completely circulate.
10. After allowing engine to cool, drain water and fill system FG006444
with proper antifreeze mixture for ambient temperature. Figure 105
Refer to coolant concentration table. See "Antifreeze
Concentration Tables" on page 4-73.
11. Run engine without radiator cap installed, so that all air will
be purged from system. Fill radiator to fill neck.
12. Drain and fill radiator coolant recovery tank.
NOTE: When refill or replace coolant, select "heater-full
hot" mode to fully open the water valve.
Coolant will then flow into the heater's core to
prevent air from being trapped in it.
EX1502246
Figure 106

4-58
Hydraulic Oil Exchange and Suction
Strainer Cleaning
WARNING
ARO1760L
Figure 107
The hydraulic tank is pressurized. Loosen the breather cap
to allow the pressurized air to vent. After the pressure has
been released, it is safe to remove either the fill cap or
service covers.
IMPORTANT
Make sure to clean any dirt or water from the top of the
hydraulic tank, especially around the fill port and filter
ports.
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,

the working conditions (extremely hot or dusty) and
the extra front end attachments being used (hydraulic
breaker, etc.), the hydraulic fluid will need to be
changed more frequently.
1. Park machine on firm and level ground. Swing upper
structure parallel to tracks. Lower boom and position
bucket on ground as shown in Figure 108.
3. Stop engine.
4. Release pressurized air from hydraulic tank by rotating
breather cap (1, Figure 111).
EX1300561
Figure 108

4-59
5. 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.
FG015943
6. Carefully remove bolts and cover (2, Figure 111) from top Figure 109
of hydraulic oil tank. There is a spring (3) under the cover
that will force the cover up.
7. Remove spring (3, Figure 111) and strainer (5), by pulling
on rod (4).
A
8. Clean inside and outside of strainer. Replace strainer if it is
broken.
9. Position strainer (5, Figure 111) on boss portion of suction
pipe (6).
NOTE: Measurement "A" is 735 mm (25.59 in).
HAOC411L
Figure 110
10. Fill the hydraulic oil tank. Check level using sight gauge on
side of tank. 1
2
11. Place spring (3, Figure 111) on rod (4) and assemble cover
(2).
12. After replacing and cleaning the hydraulic oil, filter and
strainer, vent the system. See "Venting and Priming
Hydraulic System" on page 4-80. 3
IMPORTANT 4
When the hydraulic breaker is being used, because of

the higher heat generated by this unit, use
replacement intervals recommended under the 5
"Hydraulic Oil and Filter Service Intervals" on
page 3-38.
6
13. Check level of hydraulic oil tank. (See page 4-16)
ARO1720L
Figure 111

4-60
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
Damage
Check, Adjust Valve Clearance **
Check Head Bolt Torques

4-61
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.
Always replace all related parts such as gaskets and O-rings.
Use only original equipment manufacturers parts.
Major Component Parts Name to be Exchanged Periodically Time to Exchange

Engine Fuel hose (Tank to fuel prefilter)
Fuel hose (Fuel prefilter to fuel cooler)
Fuel hose (Fuel cooler to ECU)
Fuel hose (Tank to CP pump)
Heater hose (Heater to engine)
Heater hose (Heater to radiator)
Air Conditioner hose
Hydraulic Body Pump suction hose 2 years or 4,000 hours
System Pump discharge hoses
Pump side branch hoses
Swing motor hoses
Travel motor hoses
Work Boom cylinder line hoses
Device
Arm cylinder line hoses
Bucket cylinder line hoses

4-62
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.
• In-service lifetime of hoses fitted on a machine can never
exceed 6 years, but replace hoses described in "Major
Parts - Periodic Replacement" on page 4-62, every 2
years. Always replace hoses having exceeded the allowed
in-service lifetime irrespective of the external appearance/
wear.
• Always store hoses in a dark place at a maximum of 65%
relative humidity, between 0°C (32°F) and 35°C (95°F) but
as close as possible to 15°C (59°F) and away from copper,
manganese or tube generating Ozone.

4-63
AIR-CONDITIONING SYSTEM
NOTE: See "Clean Air-Conditioning Outer Filter" on
page 4-38.
Check Control Panel

When a function switch is pushed, the last setting has to be
displayed on the LCD display.
When the light switch is turned to "I" position, the LED for
illumination in the control panel has to turn "ON".
Check Air Conditioner Hoses

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
Cooler and Air Conditioner Condenser Core" on
page 4-40.
Check Magnetic Clutch

Check the magnetic clutch for dirt and interference.
Push the "A/C" switch to energize magnetic clutch and check the
magnetic clutch.
Check Belt Tension

NOTE: See "Check Engine Fan Belt Tension" on page 4-32.

4-64
BUCKET
Bucket Tooth Replacement
WARNING
Due to the possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing bucket teeth.
Curl the bucket upwards and place the round rear surface
of the bucket firmly on the ground. 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
Figure 112
1. On a routine basis, inspect bucket teeth to make sure that

tooth wear or breakage has not developed. Do not allow
replaceable bucket teeth to wear down to a point that
bucket adapter is exposed. See Figure 112.
2. To replace a tooth (1, Figure 113), use a hammer and
punch to drive locking pin (2) and lock washer (3) out of
tooth adapter (4). 4
3. Once worn tooth has been removed, use a putty knife to 3

scrape adapter as clean as possible.
4. Slide new tooth into position and insert lock washer. 2 1 FG000346
Figure 113
5. Insert locking pin into tooth and with a hammer, drive pin in
until lock washer seats in locking groove.

4-65
Bucket O-ring Replacement
WARNING
Due to possibility of flying metal objects, always wear
safety helmet, protective gloves and eye protection when
changing pins.
FG006750
1. Inspect bucket O-rings on a routine basis. If worn or Figure 114
damaged, replacement is necessary.
2. Roll old O-ring (1, Figure 115) onto boss (2) around bucket
pin (3). Remove bucket pin and move arm or bucket link 1 4
(4) out of way. 2
ARO1390L
Figure 115
3. Remove old O-ring and temporarily install new O-ring (1,

Figure 116) onto bucket boss (2). Make sure that O-ring 1 4
groove on both bucket link (4) and boss have been 2
cleaned.
4. Realign arm or link with bucket pin hole and insert bucket
pin (3, Figure 115).
ARO1391L
Figure 116
5. Roll new O-ring (1, Figure 117) into O-ring groove.
ARO1392L
Figure 117

4-66
ELECTRICAL SYSTEM
NOTE: Never disassemble electrical or electronic parts.
Consult with a DOOSAN distributor or sales agency
before servicing.
Battery
WARNING
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.
Battery acid could cause blindness if splashed into the
eyes. If acid gets into the eyes, flush them immediately with
large quantities of water and see a doctor at once.
If you accidentally drink acid, drink a large quantity of water
or milk, beaten egg or vegetable oil. Call a doctor or poison
prevention center immediately.
When working with batteries, always wear safety glasses or
goggles.
Battery generates hydrogen gas, so there is danger of an
explosion. Do not bring lighted cigarettes near the battery,
or do anything that will cause sparks.
Before working with batteries, stop engine and turn the
starter switch to "O" (OFF) position.
Avoid short circuiting the battery terminals through
accidental contact with metallic objects, such as tool.
When removing or installing, check which is the positive (+)
terminal and negative (-) terminal.
When removing the battery, first disconnect the negative (-)
terminal. When installing the battery, first connect the
positive (+) terminal.
If the terminals are loose, there is danger that the defective
contact may generate sparks that will cause an explosion.
When installing the terminals, install them tightly.
Batteries in Cold Weather

In colder weather a greater drain is placed on the batteries when
they are used for the preheat cycle and when starting a cold
engine. Battery performance decreases as the temperature gets
lower.
In extremely cold weather, remove batteries at night and move
them to a warm location. This will help to keep them at a higher
power level.

4-67
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.
Check Charging State

FG000347
Check charging state through the charging indicator.
Figure 118
• GREEN: Sufficiently charged.
• BLACK: Insufficient charged.
• TRANSPARENT: Replace battery.
Check the Battery Terminals

Be certain that the battery is held securely in its compartment.
Clean the battery terminals and the battery cable connectors. A
solution of baking soda and water will neutralize acid on the
battery surface, terminals, and cable connectors. Petroleum jelly
or grease can be applied to the connectors to help prevent
corrosion.
Battery Replacement
When the charging indicator indicates transparency state, HAOU790L
replace the battery. The batteries should always be replaced in Figure 119
pairs.
Using an old battery with a new one will shorten the life span of
the new battery.

4-68
Fuses
1. The fuses in the fuse box are used to protect the various
electrical circuits and their components from being
O X
damaged. See Figure 120. The fuses used are standard
automotive type fuses.
2. The section on "Fuse Identification" on page 4-70, lists the
circuits and the fuse amperage required for each circuit. If
a fuse blows, determine the cause and repair any faults or
failures.
3. Do not insert a higher amperage fuse into a lower HAOC670L
amperage slot. Serious damage to the electrical Figure 120
components or fire can result.
CAUTION
AVOID INJURY
Before replacing a fuse, be sure to turn starter switch to "O"
(OFF) position.
Fuse Boxes
There are two fuse boxes (Figure 121) in the right cover behind
the seat. The fuses prevent electrical devices from overloading
or shorting.
A decal attached inside the fuse box's cover indicates the
function and amperage of each fuse.
Spare fuses are mounted on the inside of fuse box's cover. (One
each of a 10A, 15A, 20A and 30A.)
Change a fuse if the element separates. If the element of a new
FG014508
fuse separates, check the circuit and repair the circuit.
Figure 121
CAUTION
AVOID INJURY
Always replace fuses with the same type and capacity fuse
that was removed. Otherwise, electrical damage could
result.

4-69
Fuse Identification
Fuse Box (1) Fuse Box (2)
FG004974
Figure 122
Fuse Box One Fuse Box Two

No. No.
Name Capacity Name Capacity
1 Warning Light (Optional) 10A 1 Horn 10A
2 2-pump (Optional) 10A 2 Quick Coupler (Optional) 10A
3 Cigar Lighter 10A 3 Travel Alarm (Optional) 10A
4 12V Power 10A 4 Auxiliary Mode 10A
5 Wiper, Washer 10A 5 Check Connector 10A
6 Lower Wiper (Optional) 10A 6 Pilot Cutoff 10A
7 Stereo 10A 7 Memory Backup 10A
8 Starter Switch, Hour Meter 10A 8 Room Light 10A
9 Spare 30A 9 Cabin Light (Optional) 30A
10 Air Conditioner, Heater 20A 10 Work Light 20A
11 Shear, Breaker (Optional) 20A 11 Fuel Heater 20A
Instrument Panel, Pressure
12 Seat Heater (Optional) 15A 12 15A
Sensor
EPOS, Booster, Travel
13 15A 13 Headlight 15A
Speed Changer, Booster
14 ECU 15A 14 Fuel Pump (Optional), Wiper 15A

4-70
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. Contaminants in tap
water neutralize the corrosion inhibitor components. If tap water
must be used, Refer to "Table of Standards for Allowed Tap
Water" on page 4-73. Water that has been treated with a water
softener also contains salt that will cause corrosion of
components. Water from creeks and stagnant pools usually
contain dirt, minerals and/or organic material that are deposited
in the cooling system and impair cooling efficiency. As such, the
use of distilled water is recommended.
Engine coolant shall be mixed with antifreeze solution and water
in ratio of 50 : 50.
Coolant shall be checked every 500 hours of operation for
ensuring adequate concentration of antifreeze solution and
additives.
Engine overheating is often caused by bent or clogged radiator
fins. The spaces between the fins can be cleaned by use of air
or water under pressure. When straightening bent fins, use care
not to damage the tubes or break the bonding joint between the
fins and the tubes.
WARNING
Pressure at air nozzle must not exceed 2 kg/cm2 (28 psi).
Always wear goggles when using compressed air.
Do not pour cold water into radiator when engine is hot and
water level is below the top of the tubes. Such action could
result in damage to engine cylinder heads.
Heavy-duty diesel engines require a balanced mixture of water

and antifreeze. Drain and replace the mixture 1 year or
2,000 hours of operation, whichever comes first. This will
eliminate buildup of harmful chemicals.
Antifreeze is essential in any climate. It broadens the operating
temperature range by lowering the coolant's freezing point and
by raising its boiling point. Do not use more than 50% antifreeze
in the mixture unless additional antifreeze protection is required.
Never use more than 60% antifreeze under any condition.

4-71
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.
The color does not provide a standard. Unauthorized coolant
may have the same color. Please check the label on the
container. Use genuine product.
IMPORTANT
Do not mix solutions from different manufacturers.
Otherwise, the performance may be deteriorated. It is
recommended to use the standard product from DOOSAN.
In extreme temperatures, the performance of the coolant
must be checked frequently and the coolant change cycle
adjusted as necessary.
Engine parts that are made of aluminum are quickly worn
out by nitrite, and therefore you should make sure to use
nitrite-free coolant.

4-72
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) 67% 33%
-25°C (-13°F) 60% 40%
-30°C (-22°F) 56% 44%
-40°C (-40°F) 50% 50%
NOTE: The concentration shall be kept at 50% and in worst

case at 30% minimum for the least corrosion
resistance.
NOTE: Replacement cycle of the DOOSAN Genuine Product
is 2,000 hours or one year.
Table of Standards for Allowed Tap Water

Requirement
Inorganic Total
Item Sulfates Total Solids Acidity
chloride Hardness
Value < 40 ppm < 50 ppm < 9.5° d.H < 340 ppm 5.5 - 9.0
PPM (Parts Per Million) - Unit of concentration of minor materials.
• 1 ppm = 1 mg/1 kg, 1 mL/1 L
° d.H - Unit of concentration of minor materials.
• 1° d.H = 17 ppm
CAUTION
AVOID INJURY
The standard of tap water is for referece only, and may not
be regarded as a standard.
If quality of the water is not trustable, stop using tap water
whenever possible and use distilled water.

4-73
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.
Do not operate pump for more than fifteen minutes at a
time.
• Continuous usage of pump over recommended time
interval will cause overheating of motor and will result
in causing motor damage.
Do not use refueling pump for other types of fuel or fluids.
(Use only for diesel fuel.)
• Do not use refueling pump for other types of fuel
which have a low flash point.
• Do not use refueling pump for fuel contaminated with
water or high humidity. Moisture in pump mechanism
can cause rust and can create pump failure.
Always operate pump using strainer installed on inlet hose.
This will prevent any foreign materials from being
introduced into pump. Always maintain pump and all of its
components in a clean condition.
• If dirt or other foreign materials enter pump, it can
become lodged between the rotor and/or vanes and
generate heat which can cause pump damage.
• Do not remove strainer or use a strainer with larger
mesh to increase flow of fuel.
Be careful not to overfill or spill fuel.
Make sure direction of check valve is in line with flow
direction of fuel.
If any pump parts or components become lost, damaged or
inoperable, immediately replace it with a new ones.

4-74
WARNING
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.
• Check all hose clamps.
• Check transfer pump inlet port.
The transfer pump is used to transfer fuel from a refueling

source to the fuel tank. A check valve is installed in the inlet
hose to prevent fuel from flowing back from fuel tank to source.
A strainer is installed in inlet hose to prevent any foreign material
from being introduced into transfer pump or fuel tank.
A thermal limiter, built into the motor, will automatically shut off
power if motor is overheating to protect it from being damaged.
Fuel
4 3 2 5
Fuel Tank
IN OUT
FG000161
Figure 123
Reference Reference
Number Number
1 Body 4 Strainer Cap
2 Check Valve 5 Inlet Hose
3 Strainer

4-75
1. 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.
2. Insert inlet hose (5, Figure 123) into refueling tank.
3. Turn on the switch of fuel pump in the pump room.
Place the switch "I" (ON) position.
NOTE: Transfer pump rate of flow is approximately
35 lpm (9.24 U.S. gpm). Use extra care not to
overfill fuel tank so fuel does not over flow. FG015999
4. Once fuel transfer is completed, immediately turn switch to Figure 124
"O" (OFF) position to stop pump.
5. Lift inlet hose (5, Figure 123) from fueling source and turn
switch to "I" (ON) position for two - three seconds to drain
remaining fuel from hose to fuel tank.
6. Install strainer cap (4, Figure 123) on inlet strainer (3) and
return hose (5) to storage position.

4-76
HANDLING OF ACCUMULATOR
WARNING
Even though the engine is stopped, the hydraulic
accumulators for the pilot system are still charged. Do not
disconnect any pilot system hoses until accumulator
pressure has been released from the circuit. To release
pressure, turn the starter switch to "I" (ON) position and
operate all hydraulic control levers and forward/reverse
travel levers. Even though the engine is shutdown hydraulic
actuated components may move while releasing pilot
pressure. Keep all personnel away from excavator while
performing this operation.
• Move safety lever to "LOCK" position after stopping
engine.
• DO NOT mishandle accumulator(s). They are very
dangerous because they contain high-pressure
nitrogen gas.
• DO NOT punch a hole or apply heat or fire to an
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. Hydraulic oil under
pressure can penetrate the skin and cause serious
injuries.
Release pilot accumulator pressure using the following

procedure:
2. Move safety lever to "RELEASED" position.
3. Turn starter switch to "I" (ON) position.
4. Fully stroke work and travel levers in all directions.
FG016000
6. Turn key to "O" (OFF) position and remove from starter
switch. Figure 125
7. Remove accumulator by unscrewing it slowly.

4-77
TRACK TENSION
WARNING
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. Warm up the engine to prevent stalls, park the
excavator in an area that provides level, uniform ground
support and/or use support blocks when necessary.
NOTE: The track tension must be adjusted in accordance

with the operating conditions. If a lot of dust stick to
the track assembly in the working place, keep the
track as loose as possible.
Track shoe link pins and bushings wear with normal usage,
reducing track tension. Periodic adjustment is necessary to
compensate for wear and it may also be required by working
conditions.
1. Track tension is checked by jacking up one side of the
excavator. See Figure 126. Place blocking under frame
while taking measurement.
Turn the track backward 1 ~ 2 turns. 90 ~ 110
EX1300536
Figure 126
2. Measuring the distance (A, Figure 127) between the

bottom of the side frame and the top of the lowest crawler
shoe. Recommended tension for operation over most
types of terrain is as below table.
NOTE: Clean off the tracks before checking clearance
for accurate measurements.
A
3. Too little sag in the crawler track (less than clearance
distance "A" on below table) can cause excessive
component wear. The recommended adjustment can also
be too tight causing accelerated stress and wear if ground
FG000162
conditions are wet, marshy or muddy.
Figure 127

4-78
4. 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
The track adjusting mechanism is under very
high-pressure. NEVER release grease pressure too
fast. The track tension grease valve should never be
loosened more than one (1) complete turn from the
fully tightened down position. Bleed off grease
pressure slowly. Keep your body away from the valve
always. Always wear eye and face protection when
adjusting track tension.
5. Track tension adjustments are made through the grease

fitting (1, Figure 128) in the middle of each side frame.
Adding grease increases the length of an adjustment 2
cylinder (2). Extending the adjustment cylinder, increases
the pressure on the tension spring pushing the track idler
wheel outward.
6. If there is not enough slack or clearance in the tracks and
the adjustment is too tight, the idler wheel and adjusting
cylinder can be retracted by bleeding off grease through 1
hole in adjustment cylinder (2, Figure 128) 3
FG000163
Figure 128

4-79
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.
1. With the engine stopped, remove vent plug (Figure 129) to
see if any oil is present.
2. If oil is not present, fill pump with oil through port (Figure
129).
3. Install vent plug (Figure 129) first. FG016001
Figure 129
4. Start engine and run it for several minutes at low idle
engine speed. This will pressurize the hydraulic oil tank
and system.
5. Slowly loosen vent plug (Figure 129) several turns, until
hydraulic oil flows out of plug. This shows that air has been
released.
6. Tighten the plug (Figure 129).
Hydraulic Cylinders
IMPORTANT
If cylinders are operated in high idle after the hydraulic
system has been drained or the cylinder has been rebuilt,
damage to piston packing and seals can occur. Always vent
air from cylinders at low idle and at a slow speed.
1. Run engine at low idle. Extend and retract each cylinder to

within 100 mm (4 in) of fully stroking it 4 - 5 times.
2. Operate fully extend and retract each cylinder 3- 4 times.
3. Repeat procedure until cylinders extend and retract
smoothly.

4-80
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
1. Stop engine. Figure 130
2. Disconnect drain hose and fill swing motor case with

hydraulic oil.
3. Connect the drain hose.
4. Start engine and set throttle at "LOW IDLE" and swing
upper structure slowly two full revolutions to the left and
right.
Travel Motor
NOTE: Perform this only when oil is drained from travel
motor.
1. Stop engine.
2. Disconnect drain hose (Figure 131) and fill motor case with
hydraulic oil.
3. Connect drain hose.
4. Start engine and set engine speed control dial to "LOW
IDLE". Run the engine for one minute and slowly drive FG001412
excavator forwards and backwards. Figure 131
General Venting
1. After venting air from all components, shut the engine
down and check the hydraulic oil level. Fill hydraulic oil
tank to "H" mark on sight gauge.
2. Start engine and operate all controls again, run engine for
five minutes to ensure all systems have been vent and
purged of air. Move engine speed to "LOW IDLE", and
check hydraulic oil level again. Add oil as necessary.
3. Check for oil leaks and clean all fill and venting locations.

4-81
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.
Apply a coating of light oil to all of the control linkages and
control cylinders (control valve spools, etc.).
Battery Remove the battery from the excavator or remove the battery
leads from the battery to fully charge and store.
Cooling System Inspect the coolant recovery tank to make sure that the
antifreeze level in the system is at the correct level.
Every 90 days, use a hydrometer to measure the protection
level of the coolant. Refer to the antifreeze/coolant protection
chart to determine the amount of protection the cooling system
requires. Add coolant as required.
Hydraulic System Once a month, start the engine and follow the "Hydraulic Oil
Warm-up" procedures listed in this manual.

4-82
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. Inspect for damage, cracked welds or loosened
parts.
Perform all daily lubrication and service.
If the operations were in salt water or other corrosive materials,
make sure to flush the affected equipment with fresh water.
Operating in an extremely dusty or hot Clean the air intake filters on a more frequent basis.
environment. Clean the radiator and oil cooler fins to remove embedded dirt
and dust.
Clean the fuel system intake strainer and fuel filter more
frequently.
Inspect and clean as required the starter and alternator.
Operating in rocky terrain. Check the undercarriage and track assemblies for damage or
excessive wear.
Inspect for loose or damaged fittings or bolts.
Relax track tension.
On a more frequent basis, inspect the front end attachments for
damage or excessive wear.
Install a top guard and front guard as required for protection
against falling rock.
Operating in extreme cold. Use the proper fuel for the temperature conditions.
Using a hydrometer, check the antifreeze to make sure that it is
providing the proper cold weather freeze protection.
Verify the condition of the batteries. In extremely cold weather
remove the batteries at night and store them in a warmer area.
Remove mud buildup as soon as possible to prevent it from
freezing to the undercarriage and causing damage.

4-83
4-84
5Transportation
Obey all local, state or federal regulations for the transportation
of the excavator. If unsure of regulations check with local
authorities.
Check the intended route for road width, overhead clearances,
weight restrictions, and traffic control regulations. Special
approval or permits may be required.
LOADING AND UNLOADING
Warning for Counterweight and Front

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. DOOSAN is not liable for any misuse.
Never remove counterweight or front attachment unless the FG015882
upper structure is in-line with the lower structure.
Figure 1
Never rotate the upper structure once the counterweight or
front attachment has been removed.
DX235LCR Transportation
5-1
WARNING
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. If required, add blocking under the ramp for
additional support.
Make sure that ramp surface is free of grease or mud that
could cause the machine to slip or slide.
Make sure that trailer is parked on firm and level ground
before attempting to load/unload the excavator.
If it is required to turn the machine while it is on the trailer,
make sure to do this at the slowest engine and travel
speeds possible.
Make sure to secure the excavator onto the trailer as
required by local transportation laws.
Total Height Total Width Total Length Weight Remarks

5.7 m Boom
3,080 mm 2,990 mm 8,955 mm 24.3 metric tons
2.9 m Arm
(10' 1") (9' 10") (29' 5") (26.8 tons)
800G Shoe
1. Make sure that trailer is parked on firm and level ground.

See Figure 2.
2. Make sure that ramps that are being used are designed to
handle the weight of the excavator. If required, add 90 ~ 110
blocking under the ramp to provide additional support.
3. The ramp angle must be less than or not exceeding a 15°
angle. Ramps steeper than this can cause a problem when
loading or unloading.
15 FG016003
Figure 2
Transportation DX235LCR
5-2
4. Set the travel speed selector switch to "O" (OFF) position.
See Figure 3.
O
I
II
FG000023
Figure 3
5. Turn "OFF" auto idle selector button (1, Figure 4). The
indicator symbol will be disappeared. 1
6. Move engine speed to "LOW IDLE".
1 2
6 7
FG013833
Figure 4
7. If the machine is equipped with work equipment, set the

work equipment at the front, and travel forward to load it.
90 ~ 110
15 FG016003
Figure 5
8. The unit does not require disassembly for normal

over-the-road transportation. If the boom and arm need to
be removed, the counterweight will place more weight on
the rear of the machine. Make sure to back the excavator
onto the trailer so the counterweight end of the excavator is
positioned on the ramp first. See Figure 6.
15
FG016004
Figure 6
5-3
9. Extend bucket and arm cylinders to maximum length and
then lower the boom slowly.
FG016005
Figure 7
Unlock
Lock EX1300566
Figure 8
11. Stop engine by turning key to "O" (OFF) position (Figure

9). O I
12. Remove key from starter switch.
FG000175
Figure 9
13. Make sure to secure the excavator onto the trailer before
transporting. Place blocking (1, Figure 10) in front of and
behind each track. Tie front and rear (2, Figure 11) and
tie-downs point (3, Figure 11) on the lower frame with wire
cable as required by local transportation laws.
14. Refer to the Dimensions for Transportation table and 1
1
drawing for overall machine height and width
measurements. Make sure to position the excavator as
shown. If not transported in this position, the height
measurements may be different. 2
FG016006
Figure 10
5-4
2
2
2
2 3
3
3
3
FG016071
Figure 11
5-5
LIFTING MACHINE 1 1
WARNING
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.
When lifting, move the safety lever to "LOCK" position to
prevent the machine from moving unexpectedly.
Use only properly rated cables and slings
Never go in the area under or around the machine when it is
raised.
Always use the posture given in the procedure below and
use the proper lifting equipment to lift the machine.
EX1300819
1. Refer to "Specification" section of this manual for weight Figure 12
and dimensional information.
2. Lower the work equipment to the ground as shown in the
diagram on the right
3. Lower the dozer blade to the ground. (if equipped)
4. Move safety lever to "LOCK" position. Stop engine.
5. Ensure that there is nothing around the operator's
compartment, close the cab door and front glass securely.
6. Bind wire ropes between the 1st and 2nd track rollers from
the front and between the 1st and 2nd track rollers from the
rear.
7. Use spreader bars between the wire rope and the machine
to prevent damage to the rope or machine. Set the lifting
angle (1, Figure 12) of the wire rope to 30° - 40°.
8. After the machine comes off the ground, check the hook
condition and the lifting posture, and then lift slowly.
5-6
6Specification
STANDARD SPECIFICATION
Specification
Component
Metric English
CECE 3 1.06 yd3
Bucket 0.81 m
Capacity PCSA 0.92 m3 1.20 yd3
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 564 ft lb @ 1,400 rpm
Fuel Tank Capacity 320 liters 84.5 U.S. gal.
Type Bent-Axis
Discharging Pressure 370 kg/cm2 5,263 psi
Hydraulic Maximum Discharge Quantity 2 x 220.2 liters/min 2 x 58.2 U.S. gpm
Pump Tank Level 130 liters 34.3 U.S. gal.
Hydraulic Oil
Full 190 liters 50.2 U.S. gal.
Capacity
System 230 liters 60.8 U.S. gal.
Digging Bucket 16.1 metric tons 17.7 tons
Capability Arm 11.1 metric tons 12.2 tons
Swing Speed 11.3 rpm
High-speed 5.8 km/h 3.6 MPH
Travel Speed
Performance Low-speed 3.1 km/h 1.9 MPH
High-speed 12.3 metric tons 13.6 tons
Traction Force
Low-speed 23.4 metric tons 25.8 tons
Gradeability 35° (70% slope)
Ground Pressure 2 5.4 psi
0.38 kg/cm
Ground Clearance 480 mm 18.9 in
Track Shoe Width 800 mm 31.5 in
Upper Roller Qty. 2 per side
Bottom Roller Qty. 9 per side
DX235LCR Specification
6-1
OVERALL DIMENSIONS
H A
I B
J
N
M
G
F
E
P
O
K C
L D
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 m3 1.05 m3
Shipping Length A 8,955 mm (29' 4") 9,010 mm (29' 7")
Tail Swing Radius B 1,680 mm (5' 6")
Tumbler Distance C 3,650 mm (12')
Track Length D 4,445 mm (14' 7")
C/weight Clearance E 1,025 mm (3' 4")
Shipping Height (Boom) F 2,870 mm (9' 5") 2,980 mm (9' 9")
Shipping Height (Hose) G 2,955 mm (9' 8") 3,070 mm (10' 1")
Shipping Width H 3,190 mm (10' 6")
House Width I 2,870 mm (9' 5")
Cab. Width J 980 mm (3' 3")
Shoe Width K 800 mm (2' 7")
Undercarriage Width L 3,190 mm (10' 6")
Height Over Cab. M 3,080 mm (10' 1")
Cab. Height Above House N 760 mm (2' 6")
Car Body Clearance O 480 mm (1' 7")
Track Height P 947 mm (4' 10")
Specification DX235LCR
6-2
6-3
WORKING RANGE
M
K
I
d
G
Ground
E
H
D 8'
FG016008
Figure 2
6-4
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 m3 1.05 m3
Max. Digging Reach A 9,820 mm (32' 3") 9,415 mm (30' 11")
Max. Digging Reach (Ground) B 9,630 mm (31' 7") 9,215 mm (30' 3")
Max. Radius Vertical C 6,550 mm (21' 6") 6,270 mm (20' 7")
Min. Radius 8' Line D 2,570 mm (8' 5") 2,660 mm (8' 9")
Min. Digging Reach E 395 mm (1' 4") 1,630 mm (5' 4")
Min. Swing Radius F 2,310 mm (7' 7") 2,545 mm (8' 4")
Min. Loading Height G 3,155 mm (10' 4") 3,740 mm (12' 3")
Max. Vertical Wall Depth H 5,350 mm (17' 7") 5,050 mm (16' 7")
Max. Loading Height I 7,955 mm (26' 1") 7,705 mm (25' 3")
Max. Depth To 8' Line J 6,440 mm (21' 1") 5,940 mm (19' 6")
Max. Bucket Pin Height K 9,405 mm (30' 10") 9,160 mm (30' 1")
Max. Digging Depth L 6,670 mm (21' 11") 6,170 mm (20' 3")
Max. Digging Height M 10,795 mm (35' 5") 10,565 mm (34' 8")
Bucket Angle d 177° 177°
6-5
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.
Density Density Density Density

1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
401 kg/m3
Charcoal - - -
(695 lb/yd3)
433 kg/m3
Coke, blast furnace size - - -
(729 lb/yd3)
449 kg/m3
Coke, foundry size - - -
(756 lb/yd3)
801 kg/m3
Coal, bituminous slack, piled - - -
(1,350 lb/yd3)
881 kg/m3
Coal, bituminous r. of m., piled - - -
(1,485 lb/yd3)
897 kg/m3
Coal, anthracite - - -
(1,512 lb/yd3)
1,009 kg/m3
Clay, DRY, in broken lumps - - -
(1,701 lb/yd3)
1,746 kg/m3
Clay, DAMP, natural bed - - -
(2,943 lb/yd3)
1,506 kg/m3
Cement, portland, DRY granular - - -
(2,583 lb/yd3)
1,362 kg/m3
Cement, portland, DRY clinkers - - -
(2,295 lb/yd3)
1,522 kg/m3
Dolomite, crushed - - -
(2,565 lb/yd3)
1,202 kg/m3
Earth, loamy, DRY, loose - - -
(2,025 lb/yd3)
1,522 kg/m3
Earth, DRY, packed - - -
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy - - -
(2,970 lb/yd3)
Gypsum, calcined, (heated, 961 kg/m3
- - -
powder) (1,620 lb/yd3)
6-6
Density Density Density Density
1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
1,522 kg/m3
Gypsum, crushed to 3 inch size - - -
(2,565 lb/yd3)
1,810 kg/m3
Gravel, DRY, packed fragments - - -
(3,051 lb/yd3)
1,922 kg/m3
Gravel, WET, packed fragments - - -
(3,240 lb/yd3)
1,282 kg/m3
Limestone, graded above 2 - - -
(2,160 lb/yd3)
1,362 kg/m3
Limestone, graded 1-1/2 or 2 - - -
(2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed - - -
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine - - -
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock - - -
(2,160 lb/yd3)
929 kg/m3
Salt - - -
(1,566 lb/yd3)
529 kg/m3
Snow, light density - - -
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose - - -
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed - - -
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken - - -
(2,295 lb/yd3)
529 kg/m3
Sulfur, broken - - -
(891 lb/yd3)
6-7
6-8
1INDEX
Numerics C
1,000 Hour / 6 Month Service 4-46 Cabin Light 2-53
10 Hour / Daily Service 4-15 Cabin Storage Compartments 2-63
12,000 Hour / 6 Year Service 4-63 Cabin Work Light Switch 2-13
2,000 Hour / Yearly Service 4-56 Ceiling Cover 2-59
250 Hour / Monthly Service 4-30 Change Air Breather Filter 4-46
4,000 Hour / Biennial Service 4-62 Change Main Fuel Filter 4-44
50 Hour / Weekly Service 4-27 Change of Water Separator & Pre Fuel Filter (Fuel
500 Hour / 3 Month Service 4-36 Prefilter) 4-43
Charge Warning 2-22
A Check and Confirmation After Stopping Engine
Abnormal State Warning Symbols 2-27 3-12
Adjust Valve Clearance 4-61 Check Water Separator & Pre Fuel Filter (Fuel
Air Intake System 4-23 Prefilter) and Drain Water as Required 4-19
Outer Element of Air Cleaner 4-41 Cigarette Lighter 2-15
Replace Outer Air Cleaner Element 4-56 Circuit Breaker 2-53
Air-Conditioning Inner Filter 4-52 Clock 2-22, 2-36
Alternator and Starter 4-61 Cold Weather Hydraulic System Warm-up 3-10
Antifreeze Concentration Tables 4-73 Cold Weather Starting 3-6
Antivibration Shock Mounts 4-61 Communication
Ashtray 2-63 Error Warning 2-26
Audio Control Panel 2-10 Indicator 2-25
Auto Idle Mode 3-22 Component Locations 2-2
Auto Idle Selection 2-45 Constant Speed Button 2-14
Auto Idle Selector Button 2-32 Control Valve Door 2-66
Auxiliary Mode Switch 2-9 Coolant and Water for Dilution 4-8
Coolant Temperature Warning 2-23
Cooling System
B Clean Radiator, Oil Cooler and Air Conditioner
Batteries 4-35 Condenser Coil 4-40
Battery 4-67 Engine 4-71
Electrolyte Level 4-68 Engine Coolant Temperature Warning 2-23
Terminals 4-68 Oil Cooler Dust Net 4-21
Voltage 2-26 Radiator Coolant 4-57
Battery Disconnection 1-10 Refill Cooling System 4-21
Battery Explosion 1-10 Cracks and Faulty Welds 4-24
BHL Control Pattern (US Only) 1-13 Crush Hazard 1-11
Boom, Arm and Front Attachment Pins 4-27, 4-30 Cup Holder 2-64
Boost Mode 3-23 Cycle Time Tests 4-61
Booster Button 2-17
Booster Cable 3-7
Breaker Operating Precautions 3-35 D
Breaker Selection 2-45 Description of Lubrication and Service Chart 4-11
Bucket 4-65 Digital Clock 2-22
O-ring 4-66 Display Selection 2-35
Teeth and Side Cutters 4-22 Display Selector Button 2-34
Tooth 4-65 Door Side Latch 2-62
Down Arrow Button 2-34
DX235LCR Index
7-1
E Fuses 4-69
EC Declaration of Conformity 0-1 Fusible Link 2-54
Economic Mode Selector Button 2-31 Identification 4-70
Economy Mode Selection 2-44
Electric Welding Attention 1-17 G
Electrical System 4-67 Gauges
Emergency Exit 1-12 Engine Coolant Temperature Gauge 2-21
Engine Fuel Gauge 2-20
Adjust Valve Clearance 4-61 Hour Meter 2-22
Check and Adjust Engine 4-55 Hydraulic Oil Temperature 2-21
Check Warning 2-24 Multifunction Gauge 2-22, 2-25
Coolant Temperature Gauge 2-21 General Hazard 1-8
Coolant Temperature Warning 2-23 General Venting 4-81
Cover 2-66
Emergency Stop Switch 2-10
H
Fan Belt 4-32, 4-33
Handling a New Excavator 3-1
Head Bolt Torques 4-61
Handling of Accumulator 4-77
Oil and Filter 4-37
Hanger 2-64, 2-65
Oil Level 4-15
Head Bolt Torques 4-61
Oil Pressure Warning 2-23
Heater and Air Conditioner 2-47
Speed 2-26
Additional Operating Instruction 2-51
Speed Control Dial 2-9
Control Panel 2-13, 2-48
Start 3-4
Filter 4-38, 4-51
Start and Stop 3-2
Location of Controls and Vents 2-47
Stopping 3-11
Memory Function of Used Mode 2-51
Entanglement in Rotating Parts 1-9
Refrigerant 4-53
ESC Button 2-35
System 4-64
Excavator Rated Lift Capacity Tables 1-56
Home Button 2-34
Horn Button 2-16
F Hose Clamps 4-35
Fall Hazard 1-12 Hot Pressurized Fluid 1-9
Falling Object (Optional) 1-15 Hot Surface 1-12
Fan Belt 4-29 Hour Meter 2-22
Filter / Oil Info 2-37 Hydraulic Attachments (Optional) 3-34
Filter State 2-27 Hydraulic Breaker (Optional) 1-17
Flow Control 2-42 Hydraulic Oil Check (Optional) 1-16
Flow Control Button 2-32 Hydraulic System
Flying Debris or Objects 1-11 Flow Control 2-42
Front Front Hydraulic Pump Pressure 2-27
Bottom Window 2-61 General Venting 4-81
End Attachments 4-35 Hydraulic Breaker
Hydraulic Pump Pressure 2-27 Hydraulic Hoses and Tubing 3-34
Upper Windows 2-60 Oil and Filter 3-38
Windows 2-60 Selection 3-34
Fuel Hydraulic Cylinders 4-80
Filter 4-44 Hydraulic Oil Exchange 4-59
Gauge 2-20 Hydraulic Oil Return Filter 4-35, 4-47
Heater Switch 2-18 Hydraulic Oil Tank 4-16
Level 4-18 Hydraulic Oil Temperature Gauge 2-21
System 4-44 Leaks in the Hydraulic System 4-17
Transfer Pump 4-74 Main System Pump 4-80
Transfer Pump 4-74 Oil Exchange 4-59
Fuse Rear Hydraulic Pump Pressure 2-27
Boxes 2-54, 4-69 Swing Motor 4-81
Index DX235LCR
7-2
Warm-up 3-9 Multifunction Gauge 2-22, 2-25
I N
Impact Hazard (Optional) 1-13 Nuts and Bolts 4-35
Indicator
Communication Indicator 2-25 O
Indicator Lights Oil Cooler Dust Net 4-21
Charge Warning 2-22 Oil Level of Travel Reducer 4-45
Coolant Temperature Warning 2-23 Opening the Window 2-60
Engine Check Warning 2-24 Operating 3-20
Engine Oil Pressure Warning 2-23 Instructions 3-21
Preheating Indicator 2-24 Precautions 3-27
Warning Light 2-24 Operation 3-1
Work Light 2-24 Operation In
Information and Location for Safety Decals 1-6 Extreme Cold 3-44
Inspecting Engine Before Starting 3-2 Extreme Heat 3-45
Instrument Panel 2-17, 2-19 High Altitudes 3-48
Intermittent Speed Button 2-14 Rainy or Humid Conditions 3-47
ISO Control Pattern 1-13 Salt Water Areas 3-48
Operation of All Switches 4-24
K Operation Selection Display 2-44
Keep Bystanders Away 1-9 Operation Under Unusual Conditions 3-44
Operational Checks Before Starting Engine 3-3
L Operational Controls and Panels 2-6
Language 2-36 Operator's Area 2-4
Leaks in the Fuel System 4-18 Operator's Compartment Light 2-53
Leaks in the Hydraulic System 4-17 Other Signal Words 1-3
Levers Outer Air Cleaner Element 4-56
Adjusting Reclining 2-56 Outer Element of Air Cleaner 4-41
Adjusting the Seat Forward 2-55 Overall Dimensions 6-2
Adjusting the Seat's Angle 2-55 Overload Warning Switch (Optional) 2-18
Angle Adjustment of Armrest 2-56
Safety Lever 2-18 P
Lift/Tie down (Optional) 1-17 Panels
Lifting Machine 5-6 Air Conditioner Control Panel 2-13
Lifting Objects 3-42 Audio Control 2-10
light Switch 2-12 Heater and Air Conditioner 2-47
Lights Heater and Air Conditioner Control Panel 2-48
Cabin 2-53 Instrument 2-17
Loading and Unloading 5-1 Instrument Panel 2-19
Locking the Pedal 3-20 Wiper Switch Panel 2-14
Long Term Storage 4-82 Parking Excavator 3-32
Lubrication and filters 3-2 Password
Lubrication and Service Chart 4-10 Activated 2-20
Set Password 2-40
M Password Activated 2-20
Magnetic Clutch 4-64 Pilot Cutoff Switch 2-53
Main Menu 2-33 Pilot Filter 4-35, 4-48
Maintenance in Special Conditions 4-83 Pins and Bushings 4-35
Maintenance Intervals 4-13 Power Boost Selection 2-45
Miscellaneous Access Doors 2-66 Power Mode 3-21
Mode Selection 3-21 Power Mode Selection 2-44
Mode Selector Buttons 2-31 Power Mode Selector Button 2-31
Power Socket 2-15
DX235LCR Index
7-3
Preheating Light 2-24 Check and Confirmation After Stopping Engine
Preliminary Work Machine Setup for Maintenance 3-12
4-4 Engine Shutdown 3-11
Pressurized Gas and Fluid 1-11 Parking Excavator 3-32
Preventive Maintenance 4-1 Side Door 2-66
Pump Pressure Specification 6-1
Front Pump 2-27 Standard Mode Selection 2-44
Rear Pump 2-27 Standard Specification 6-1
Starter Switch 2-8
Q Starting Engine Using a Booster Battery 3-7
Quick Coupler Operation Selection (Oprional) 2-46 Start-up
Quick Coupler Switch (Optional) 2-9 Cold Weather Hydraulic System Warm-up 3-10
Cold Weather Starting 3-6
Engine Start 3-4
R Hydraulic System Warm-up 3-9
Radiator Coolant 4-57 Inspection Before Starting Engine 3-2
Rear Hydraulic Pump Pressure 2-27 Operational Checks Before Starting Engine 3-3
Refill Cooling System 4-21 Starting Engine Using a Booster Battery 3-7
Roll Over Protective Structure (ROPS) 1-40 Stereo 2-52
ROPS Certification 1-40 Audio Control Panel 2-10
ROPS Warning (Optional) 1-14 Straight Travel Pedal (Optional) 3-19
Rotating Buttons 2-16 Structural Damage 4-61
Rotating Fan 1-10 Suction Strainer 4-59
Sun Visor 2-64
S Swing
Safety Decals 1-4 Bearing 4-28
Safety Decals With Text 1-4 Gear and Pinion 4-36
Safety Decals Without Text (No-Text) 1-5 Motor 4-81
Safety Lever 2-18, 3-13 Reduction Device 4-20, 4-45, 4-46, 4-50
Safety Precautions 4-3 Switches
Seat 2-55 Auto Idle Selector Button 2-32
Seat Adjustment Automatic Travel Speed Control 3-15
Adjusting Reclining 2-56 Auxiliary Mode 2-9
Adjusting the Seat Forward 2-55 Booster Button 2-17
Adjusting the Seat's Angle 2-55 Cabin Work Light Switch 2-13
Adjustment of Lumbar Support 2-56 Cigar Lighter 2-15
Air Suspension Seat 2-58 Constant Speed Button 2-14
Angle Adjustment of Armrest 2-56 Display Selector Button 2-34
Headrest 2-56 Down Arrow Button 2-34
Left ad Right Control Stand Location 2-58 Economic Mode Selector Button 2-31
Seat Belt 1-34, 2-57, 4-23 Engine Emergency Stop 2-10
Seat Warmer Switch (Optional) 2-16 Engine Speed Control 3-21
Selection Button 2-34 Engine Speed Control Dial 2-9
Selection of ESC Button 2-35
Breaker 2-44, 2-45 Flow Control Button 2-32
Overload Alarm 2-45 Fuel Heater 2-18
Power Boost Selection 2-44 Home Button 2-34
Quick Coupler Operation 2-46 Horn Button 2-16
Shear 2-44, 2-45 Intermittent Speed Button 2-14
Serial Numbers 4-3 light Switch 2-12
Set Password 2-40 Overload Warning (Optional) 2-18
Setting Clock 2-36 Pilot Cutoff Switch 2-53
Shear Buttons 2-17 Power Mode Selector Button 2-31
Shear Selection 2-45 Power Socket 2-15
Shutdown Quick Coupler (Optional) 2-9
Index DX235LCR
7-4
Rotating Buttons 2-16 Unloading and Loading 5-1
Seat Warmer (Optional) 2-16 Up Arrow Button 2-33
Selection Button 2-34
Shear Buttons 2-17 V
Starter Switch 2-8 Venting and Priming Hydraulic System 4-80
Travel Speed Selector Switch 2-11 General Venting 4-81
Travel/Swing Alarm (Optional) 2-15 Hydraulic Cylinders 4-80
Up Arrow Button 2-33 Main System Pump 4-80
Warning Light Switch 2-13 Swing Motor 4-81
Washer Button 2-14 Visibility Information 1-18
Symbols
Air Cleaner Clogged Warning 2-29
Hydraulic Oil Overheat Warning 2-28 W
Return Filter Clogged Warning 2-29 Warning Light 2-24
Warning Light Switch 2-13
Warning Tag - "Do Not Operate" 1-9
T Washer Button 2-14
Table of Recommended Lubricants 4-6 Water Separator 4-19
Tie down (Optional) 1-17 Weight of Workload Materials 6-6
Towing Procedure 3-33 Welding Repairs 1-46
Track Assemblies 4-29 Window Washer Liquid 4-22
Track Tension 4-78 Windows
Transportation 5-1 Front 2-60
Travel 3-14 Front Bottom 2-61
Control Lever Operation 3-16 Front Upper 2-60
Instructions 3-17 Opening 2-60
Reduction Device 4-45, 4-49 Sun Visor 2-64
Speed Selector Switch 2-11 Wiper Switch Panel 2-14
Travel/Swing Alarm Switch (Optional) 2-15 Work Levers (Joysticks) (ISO Pattern) 3-24
Work Light Indicator 2-24
U Working Range 6-4
Ultra Low Sulfur Diesel Fuell (Optional) 1-14
DX235LCR Index
7-5
Index DX235LCR
7-6
WARNING: Cancer and Reproductive Harm.
For more information go to www.P65 warnings.ca.gov.
WARNING: Breathing diesel engine exhaust exposes you to

chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated
area.
• 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

Doosan Dx235lcr

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EXCAVATOR

Serial Number 5001 and Up

DOOSAN and the DOOSAN logo are registered

Operating Controls ....................................................................2-1

DX235LCR Table of Contents

Inspection, Maintenance and Adjustment...............................4-1

Table of Contents DX235LCR

DX235LCR Table of Contents

Doosan Benelux SA, Drève Richelle 167, 1410 Waterloo, (Belgium), 

Please respect the importance of taking responsibility for your

SAFETY ALERT SYMBOL

Other Signal Words

NOTE: The word "NOTE" identifies information for effective

Safety Decals With Text

3. Keep Bystanders Away (950205-03803)

4. Hot Pressurized Fluid (950205-03781)

5. Entanglement in Rotating Parts (950205-03791)

7. Battery Explosion (950205-03785)

8. Battery Disconnection (950205-03784)

• Track adjusting systems use grease under high-

10. Crush Hazard (950205-03805)

11. Pressurized Gas and Fluid (950205-03782)

13. Hot Surface (950205-03777)

14. Emergency Exit (950205-03810)

BHL Control Pattern (US Only) (950205-03868)

16. Impact Hazard (Optional) (950205-03963)

18. ROPS Warning (Optional) (950205-03861)

22. Lift/Tie down (Optional) (950205-03815)

23. Tie down (Optional) (950205-03816)

24. Electric Welding Attention (950212-02440)

Your machine may be equipped with visual aids; mirrors or

To lift safely while in Digging Mode, the following items must be

Always engage the "Digging Mode" control on the Instrument

Inside Operator's Cabin

Breathing Masks, Ear Protection May Be

Vibration Level Information

Fuel, Oil and Hydraulic Fluid Fire Hazards

Asbestos Dust Hazard Prevention

Fire Extinguisher and First Aid Kit

Never attempt to alter or modify any protective structure

Work Site Precautions

Minimum levels of insurance coverage, work permits or

Checks Before Starting Engine

When Swinging or Changing Direction of

• Sound the horn to warn people in the area. Figure 20

• Check that there is no one in the area around the machine.

Never turn the starting switch to "O" (OFF) position when

When traveling on rough ground, travel at low speed, and avoid

When using the machine, to prevent accidents caused by

Avoid High-voltage Cables

Voltage Minimum Safe Distance

Use these minimum distances as a guideline only. Depending

In a work site where falling rocks can cause damage and

Operate Carefully on Snow, Ice and in Very

Snow accumulation could hide or obscure potential hazards.

When the temperature rises, frozen road surfaces become soft,

In cold weather, do not touch metal surfaces with your bare

Never Let Anyone Ride on Attachment

Clean Before Inspection or Maintenance

Fire Prevention and Explosion Prevention

7 6.33 6.33 6.20 6.20 *5.14 4.86 @5.88

6 6.88 6.88 6.46 6.38 6.20 4.64 *5.06 3.87 @6.62