service repair manual

1. K1036951E Shop Manual
Copyright 2007 DOOSAN
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Shop Manual
K1036951E
Serial Number 5001 and Up
DX30Z

2. Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Safety......................................................................... SP001061
Specifications
Specification for DX30Z........................................................................ SP001394
General Maintenance
General Maintenance Procedures........................................................ SP000016
Standard Torques................................................................................. SP000813
Upper Structure
Cabin .................................................................................................... SP001063
Swing Bearing....................................................................................... SP001064
Lower Structure and Chassis
Track Assembly .................................................................................... SP001395
Engine and Drive Train
Engine................................................................................................... SP001254
Drive Coupling (Main Pump)................................................................. SP001066
Hydraulics
Accumulator.......................................................................................... SP000028
Center Joint (Swivel)............................................................................. SP001067
Cylinders............................................................................................... SP001396
Swing Motor.......................................................................................... SP001400
Travel Motor.......................................................................................... SP001102
Main Pump............................................................................................ SP001433
Main Control Valve ............................................................................... SP001071

3. Table of Contents
Page II
Remote Control Valve (Work Lever / Joystick)..................................... SP001072
Travel Control Valve ............................................................................. SP000839
Pedal Valve........................................................................................... SP001073
Hydraulic Schematic (DX30Z) .............................................................. SP001397
Electrical System
Electrical System .................................................................................. SP001142
Electrical Schematic (DX27Z/DX30Z)................................................... SP001144
Attachments
Working Attachments............................................................................ SP001398
Bucket................................................................................................... SP001076

4. SP001061
Page 1
Track Excavator Safety
SP001061
TRACK EXCAVATOR SAFETYSP001061
Track
Excavator
Safety
Edition 1

5. SP001061
Page 5
Track Excavator Safety
SAFETY PRECAUTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling the load.
Remember, that ultimately safety is your own
responsibility.
MODEL SERIAL NUMBER RANGE
DX27Z 5001 and Up
DX30Z 5001 and Up
DX35Z 5001 and Up

6. SP001061Track Excavator Safety
Page 6
TO THE OPERATOR OF A
EXCAVATOR
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. “General Safety Essentials” on page 1-10
2. “Location of Safety Labels” on page 1-11
3. “Summary of Safety Precautions for Lifting in Digging
Mode” on page 1-11
4. “Unauthorized Modifications” on page 1-13
5. “General Hazard Information” on page 1-13
6. “Before Starting Engine” on page 1-22
7. “Machine Operation” on page 1-26
8. “Maintenance” on page 1-33
9. “Battery” on page 1-41
10. “Towing” on page 1-43
11. “Shipping and Transportation” on page 1-44
12. “Lifting With Sling” on page 1-44
DANGER!
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.

7. SP001061
Page 7
Track Excavator Safety
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.

8. SP001061Track Excavator Safety
Page 8
Learn the Signal Words Used with the
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 the "Exclamation
Point" symbol.
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 should be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
CAUTION!
This word is used on safety messages and safety labels and
indicates potential threat 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!
This word is used on safety messages and safety labels and
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!
This word is used on safety messages and safety labels and
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.

9. SP001061
Page 9
Track Excavator Safety
Safety precautions are described in SAFETY from page -11 on.
DOOSAN cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore the
safety messages in this manual and on the machine may not
include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual
are used, you must be sure that you and others can do such
procedures and actions safely and without damaging the
machine. If you are unsure about the safety of any procedures,
contact a DOOSAN distributor.

10. SP001061Track Excavator Safety
Page 10
GENERAL SAFETY ESSENTIALS
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN for proper installation and application.
Lifting-work applications (unless restricted or prohibited by local
regulations) are permitted in approved lift configuration, to rated
capacity only, with no side-loading. DO NOT use the machine
for activities for which it was not intended. DO NOT use the
bucket for lifting work, unless lift slings are used in the approved
configuration.
Use of an accessory hydraulic hammer (breaker), work in rough
terrain, demolition applications or other hazardous operation
may require installation of additional protective structures to
safeguard the operator.
Lifting Capacity Rating Configuration
Lifting capacity ratings that are printed at the end of this safety
section are based on the machine being level, on a firm
supporting surface, with hooks and slings attached in approved
configuration. Loads must be balanced and supported evenly.
Use tag lines to keep the load steady if wind conditions and
large surface area are a problem. Work crew hand signals,
individual tasks and safe procedures should all be universally
understood before the lift is made.
IMPORTANT
Before using the excavator to make lifts check municipal
and regional regulations or statutes that could apply.
Governing ordinances may require that all heavy lifting be
done with single purpose equipment specifically designed
for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that
can be used for digging, loading, grading or other work may
be expressly forbidden by a regional injunction or other
legal prohibition. Always follow all the other instructions,
guidelines and restrictions for Safe Lifting in the Operation
and Maintenance Manuals.

11. 1Lower Structure and
Chassis

12. SP001395
Page 5
Track Assembly
SAFETY PRECAUTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
MODEL SERIAL NUMBER RANGE
DX30Z 5001 and Up

13. SP001395Track Assembly
Page 6
CRAWLERS
Specification and Construction
Steel Crawlers
Track Frame
Figure 1
TRACK FRAME
UPPER ROLLER
IDLER
GUIDE LOWER ROLLER TRACK SPRING FG008455
Figure 2

14. SP001395
Page 7
Track Assembly
Disassembly and Reassembly
Crawler Removal
Crawler removal operation may very dangerous as it should be done
with the machine inclined. Never move the machine during removal
operation so that the machine may not be tipped over.
When loosening the cartridge valve, do not bring your face near
the grease nipple because the inside of the track tension
adjusting cylinder is in a high pressure state and allow highly
pressurized grease to splash, with the result that the grease
nipple may pop out.
Crawler loosening
1. Loosening the cartridge valve of the tension adjusting
cylinder drains the grease to loosen the crawlers. Loosen
the cartridge valve slowly.
• The maximum amount of loosening can be obtained
if 1/2 turn is made.
2. When removing the crawlers, position the machine as
shown and install non-slip supports under the frames.
• If the grease would not be drained out easily, turn the
crawlers a little in the position as shown.
3. After completing the tension adjustment, tighten the valve
securely.
• Cartridge tightening torque: 6~9kg•m
Crawler removal
1. Lift the machine in one side using the front and install wood
block under the machine.
2. Steel Crawlers
Remove the master pin(1) from the linkage by turning it to
the idler side, and then remove the crawler(2).
1
FG008457
Figure 2
FG007575
90 ~ 100
Figure 3
Figure 4

15. SP001395Track Assembly
Page 8
3. Rubber Crawlers
Slide in the idler all the way, and remove the rubber
crawler from the idler using a steel bar.
Crawler Installation
Crawler installation operation may very dangerous as it should
be done with the machine inclined. Never move the machine
during removal operation so that the machine may not be tipped
over.
1. Crawler installation
• Lift the machine in one side using the front and install
wood block under the machine.
• Index the crawler(2) with the sprocket teeth and then
install it on top of the idler.
• For steel crawlers, insert the master pin(1).
For rubber crawlers, install the crawler over the idler.
2. Track tension adjustment
• With a grease gun, inject grease into the grease
nipple.
Figure 5
Figure 6
FG008460
Figure 7

16. SP001395
Page 9
Track Assembly
• Check
Measure the distance between the rolling surface of
the track roller and the contact surface of the crawler.
A. For steel crawlers
It is accepted if the distance between the rolling
surface of the track roller and the contact surface of
the crawler is 10~15mm.
B. For rubber crawlers
It is accepted if the distance between the rolling
surface of the track roller and the contact surface of
the crawler is 10~15mm.
Make sure that the tension is properly adjusted.
If tension is proper, tighten the cartridge valve.
Tightening torque: 6~9kg•m
If tension is difficult to adjust although grease was injected, it
indicates that the pin and bush have been severely worn. The
bush must be replaced. For rubber crawlers, check the track
tension adjusting cylinder seal and replace the seal, if
required.
10~15mm
FG007705
Figure 8
Figure 9
Figure 10

17. SP001395Track Assembly
Page 10
Maintenance Standards
Steel crawlers
Figure 11
No. Check Item Standard Limits Remarks
1 Link Pitch 101.6 mm 104 mm When measuring 5 links
2 Link Height 60 mm 57.5 mm Build up or replace
3 Crawler Height 6.5 ±1.5mm 7 mm Build up or replace
4 Pin Clearance 0.33 mm 2 mm Replace
5 Bush Thickness 32.2 mm 29 mm Replace

18. SP001395
Page 11
Track Assembly
Track frame spring
4
1
23
FG008723
Figure 12
No. Item Criteria Remarks
1 Deformed frame
Limit
Bent
Bending 5 (Overall length of track frame)
Distorted
10 (Distortion between left and right
crawler frames)
Widened idler 5 mm
2
Gap between upper
and lower sides of
idler guide
Standards Limits
Build up or replaceTrack frame 102 mm 107 mm
Idler frame 100 mm 95 mm
3
Gap between left and
right of idler guide
Track frame 148 mm 153 mm
Build up or replace
Idler support 145.5±1.0 mm 140.5 mm
4
Track spring
(Free length)
Free length Installed length
Replace
286.5 mm 233.5 mm

19. SP001395Track Assembly
Page 12
Rubber crawler features
The amount of friction of the rubber crawler sets the limit of use.
However, it is subject to change depending upon the work
condition and environment.
0
5
10
15
20
500 1000 1500 2000 2500 3000
FG008467
Amount of friction
Operating hours(H)
Limit of use
Figure 13
Figure 14
Figure 15
Item DX30Z
Distance between centers of crawlers 4,400±10
Scale cord Rigid 800 kg
Scale cord No. of coils 40±4
Range of temperature of use -25°C~55°C
Width x Pitch 300x52.5 mm

20. SP001395
Page 13
Track Assembly
IDLER
Construction
Figure 16
Reference
Number
Description
1 Front idler assembly
2 Idler
3 Shaft
4 Bearing (BL-207)
5 C-type stopper ring
6 Oil seal (QLF 35, 72, 13, 20)
7 Guide
8 Spring pin (∅10x50L)
Reference
Number
Description

21. SP001395Track Assembly
Page 14
Disassembly and Reassembly
Disassembly procedures
1. Refer to "Crawler Disassembly" to remove the crawlers
and then idler assembly.
2. Remove the spring pin(8) from the guide(7).
3. Remove the guide(7) from the shaft(3).
4. Remove the oil seal(6) using a screw driver.
• Once removed, the oil seal should not be reused.
5. Remove the C-type stopper ring(5), bearing(4), and
shaft(3).
Reassembly procedures
1. For reassembly, reverse the disassembly procedures.
• Clean segregated parts.
• Coat clean gear oil or engine oil(80cc) before
assembling the oil seal(6).
• Refer "Crawler Installation" for crawler reassembly.
Idler (for steel crawlers)
Figure 17
No. Item Unit Standard Limits Remarks
1 Outside diameter mm ∅311 ∅287 Build up or replace
2 Contact outside diameter mm ∅269 ∅265 Build up or replace
3 tab width mm 26.2 22 Build up or replace
4 Overall width mm 65 60 Build up or replace
5 Contact width mm 19.4 24 Build up or replace
6 Lubricant volume cc 80 80 Gear oil

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23. SP001395
Page 15
Track Assembly
Idler (for rubber crawlers)
Figure 18
No. Item Unit Standard Limits Remarks
1 Outside diameter mm ∅311 ∅287 Build up or replace
2 Contact outside diameter mm ∅269 ∅265 Build up or replace
3 tab width mm 26.2 22 Build up or replace
4 Overall width mm 65 60 Build up or replace
5 Contact width mm 19.4 24 Build up or replace
6 Lubricant volume cc 80 80 Gear oil

24. SP001395Track Assembly
Page 16
TRACK TENSION ADJUSTING
CYLINDER
Construction
FG010043
1
2
3 45
6
7 8 9
10
11
Figure 19
Reference
Number
Description
1 Rod
2 Cylinder
3 Yoke
4 Spring
5 Nut_Lock
6 Pin_Split
7 O-ring (1BPP30)
8 Backup Ring(T2-P40)
9 Packing (DSI 0, 48.5t)
10 Grease Valve
11 Grease Nipple
Reference
Number
Description

25. SP001395
Page 17
Track Assembly
Spring Specifications
Figure 20
Designation Dimensions Designation Dimensions
No. of active coils 7.5 Minimum closed length 203.5
Total No. of coils 9 Outside diameter 107
Spring constant (kg/mm) 50.9 Mean diameter 85
Set load (kg) 2698 Inside diameter 63
Compressive load (kg) 4225 Wire diameter 22
Free length (mm):L0 286.5 Set length 233.5