service repair manual

1. K1043970AE Shop Manual Copyright 2008 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
K1043970AE
Serial Number 40001 and Up
DX15 / DX18

2. Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Safety......................................................................... SP001521
Specifications
Specification for DX15/DX18 ................................................................ SP001522
General Maintenance
General Maintenance Procedures........................................................ SP000016
Standard Torques................................................................................. SP000813
Upper Structure
Lower Structure and Chassis
Track Assembly .................................................................................... SP001523
Engine and Drive Train
Engine................................................................................................... SP001524
Hydraulics
Center Joint (Swivel)............................................................................. SP001525
Cylinders............................................................................................... SP001526
Swing Motor.......................................................................................... SP001527
Travel Motor (With Gear Box)............................................................... SP001528
Pilot Control Valve (Work Lever / Joystick)........................................... SP001529
Main Pump............................................................................................ SP001530
Main Control Valve ............................................................................... SP001531
Solenoid Valve...................................................................................... SP001532
Hydraulic Schematic (DX15/DX18)....................................................... SP001681

3. Table of Contents
Page II
Electrical System
Electrical System .................................................................................. SP001534
Electrical Schematic (DX15/DX18)....................................................... SP001535
Attachments
Boom and Arm...................................................................................... SP001536
Bucket................................................................................................... SP001550

4. SP001521
Page 1
Track Excavator Safety
SP001521
TRACK EXCAVATOR SAFETYSP001521
Track
Excavator
Safety
Edition 1

5. SP001521
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 load.
Remember, that ultimately safety is your own personal
responsibility.
MODEL SERIAL NUMBER RANGE
DX15 40001 and Up
DX18 40001 and Up

6. SP001521Track Excavator Safety
Page 6
TO THE OPERATOR OF A
DOOSAN 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 1-8
2. “Location of Safety Labels” on page 1-8
3. “Work Site Precautions” on page 1-9
4. “Operation” on page 1-13
5. “Equipment” on page 1-19
6. “Maintenance” on page 1-24
7. “Shipping and Transportation” on page 1-28
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. SP001521
Page 7
Track Excavator Safety
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
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 of a hazardous situation that, if not
avoided, could result in serious injury or death. It may also
be used to alert against a highly unsafe practice.
DANGER
Indicates 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
explode or detonate if handled or treated carelessly.

8. SP001521Track Excavator Safety
Page 8
GENERAL SAFETY ESSENTIALS
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket.
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.
Never use machine for lifting.
The excavator is designed for excavating and loading only.
The excavator is not equipped for lifting and does not have
safety devices for lifting.
LOCATION OF SAFETY LABELS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization or written approval
from DOOSAN can create a safety hazard, for which the
machine owner must 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 in which the safety
of critical assemblies is dangerously compromised.
HKA1013L
Figure 1

9. SP001523
Page 1
Track Assembly
SP001523
TRACK ASSEMBLY SP001523
Track
Assembly
Edition 1

10. SP001523
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
DX15 40001 and Up
DX18 40001 and Up

11. SP001523Track Assembly
Page 6
GENERAL DESCRIPTION
The track assembly is composed of the following major
components:
1. Track
2. Front Idler Roller
3. Upper Roller
4. Lower Roller
5. Track Spring and Track Adjustment Cylinder
TRACK TENSION
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 1. Place blocking under frame while
taking measurement.
WARNING
Safely measuring track tension requires two people. One
person must be in the operator's seat, running the controls
to keep one side frame in the air, while the other person
makes dimensional checks. Take all necessary precautions
to make sure the machine won't move or shift position
during service. Warm up the engine to prevent stalls, travel
the excavator to an area that provides level, uniform ground
support and/or use support blocks when necessary.
The track adjusting mechanism is under very
high-pressure. NEVER release pressure too suddenly. The
grease cylinder valve should never be backed off more than
1 complete turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
HKA1304L
Figure 1

12. SP001523
Page 7
Track Assembly
2. Measure the distance (A, Figure 2) between the rolling
surface of the track roller and the contact surface of the
crawler.
NOTE: This measurement can be thrown off if there is
too much mud or dirt or other material in the
track assembly. Clean off the tracks before
checking clearance.
A. 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 - 15 mm (0.39 - 0.59 in).
3. Too little sag in the crawler track can cause excessive
component wear. The recommended adjustment can also
be too tight causing accelerated stress and wear if ground
conditions are wet, marshy or muddy, or if the ground is
hard and full of rocks or gravel.
4. Track tension adjustments are made through the grease
fitting (1, Figure 4) in the middle of each side frame. Adding
grease increases the length of the adjustment cylinder.
The longer the adjustment cylinder, the greater the
pressure on the tension spring pushing the track idler
wheel outward.
5. If there isn't 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 thru hole
in adjustment cylinder.
6. After completing the tension adjustment, tighten the valve
securely.
NOTE: Cartridge tightening torque: 6 - 9 kg• m (43 -
65 ft lb).
Figure 2
Figure 3
WARNING
The track adjusting mechanism is under very
high-pressure. NEVER release pressure too suddenly. The
grease cylinder valve should never be backed off more than
1 complete turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away from
the valve at all times.
Figure 4

13. SP001523Track Assembly
Page 8
CLEANING AND INSPECTION
(WEAR LIMITS AND TOLERANCES)
The tables that follow provide factory specified dimensional
limits (as new condition, recommended service and replacement
limit) for lower travel frame components.
Recommended maintenance to renew most listed components
requires welding on additional material and grinding off excess.
Some components must be replaced before the service limit is
exceeded. No maintenance or renewal is possible.
Compare the values in the tables with dimensions and profiles
shown in the following figures.
Rubber Tracks
The amount of friction on the rubber track shoes determines the
limit of use. However, it is subject to change depending upon the
work condition and environment.
CAUTION
Refer to the "Welding Precautions and Guidelines"
information in "General Maintenance Procedures" section for
general recommendations and specific safety precautions,
before starting any lower travel frame component rebuilding
procedure.
20
15
10
5
0 500 1000 1500 2000 2500 3000
HKA1313L
A B C
WearAmount(mm)
Operating Hours
Figure 5
Reference Number Description
A Concrete Surface
B Normal Use
C Dirt

14. SP001523
Page 9
Track Assembly
A
B
C
D
E
F
HBOH840L
Figure 6
Reference
Number
Description
A 25.0 mm
(0.98 in)
B 26.0 mm
(1.02 in)
C 25.0 mm
(0.98 in)
D 23.5 mm
(0.93 in)
E 22.0 mm
(0.87 in)
F 230.0 mm
(9.06 in)
Reference
Number
Description
A
HKA1315L
Figure 7
Reference
Number
Description
A Pitch 96.0 mm (3.78 in)
Item DX15/DX18
Distance Between Centers of Shoes
4,410 ±12 mm
(173.62 ±0.47 in)
Scale Cord
Rigid
800 kg
(1,764 lb)
No. of Coils 40 ±4 Coils
Operating Temperature Range
-25°C - 55°C
(-13°F - 131°F)
Width x Pitch
230 x 96 mm
(9.06 x 3.78 in)

15. SP001523Track Assembly
Page 10
Track Frame Spring
HKA1312L
Figure 8
Item Limit Remarks
Deformed Frame
Bending
5.0 mm (0.20 in)
(Overall length of track frame)
Bent
Distorted
10.0 mm (0.39 in)
(Distortion between left and right crawler frames)
Widened Idler 5.0 mm (0.20 in)
Item
Normal (New)
Dimension
Recommended
Limit for
Maintenance
Remarks
Gap between upper and lower
sides of idler guide
Track Frame
51.0 mm
(2.01 in)
56.0 mm
(2.20 in)
Rebuild or
Replace
Idler Frame
50.0 mm
(1.97 in)
45.0 mm
(1.77 in)
Rebuild or
Replace
Gap between left and right of
idler guide
Track Frame
153.0 mm
(6.02 in)
158.0 mm
(6.22 in)
Rebuild or
Replace
Idler Support
150.0 ±1.0 mm
(5.91 ±0.04 in)
145.0 mm
(5.71 in)
Rebuild or
Replace
Item Free Length Mounted Length Remarks
Track Spring
261.0 mm
(10.28 in)
223.0 mm
(8.78 in)
Replace

16. SP001523
Page 11
Track Assembly
Idler (For Steel Shoes)
A
B
C
D
HKA1402L
Figure 9
No. Item Unit Standard Limits Remarks
A
Outside
Diameter
mm
(in)
ø292.0
(11.49)
ø288.0
(11.34)
Rebuild or Replace
B PCD
mm
(in)
ø277.18
(10.91)
- Rebuild or Replace
C
Dedendum
Diameter
mm
(in)
ø253.0
(9.96)
- Rebuild or Replace
D Face Width
mm
(in)
22.0
(0.87)
- Rebuild or Replace

17. SP001523Track Assembly
Page 12
Track Roller
AB
C
D
E
F
G
HKA1602L
Figure 10
No Item Unit Standard Limits Remarks
A Outside Diameter
mm
(in)
ø100.0
(3.94)
– Rebuild or Replace
B Contact Surface Diameter
mm
(in)
ø80.0
(3.15)
ø78.0
(3.07)
Rebuild or Replace
C Tab Width
mm
(in)
22.0
(0.87)
17.0
(0.67)
Rebuild or Replace
D Overall Width
mm
(in)
80.0
(3.15)
– Rebuild or Replace
E Contact Width
mm
(in)
29.0
(1.15)
– Rebuild or Replace
F Side Clearance
mm
(in)
0.2 ±0.1
(0.008 ±0.004)
1.5
(0.059)
Replace Bushing
G Tightening Torque
kg•m
(ft lb)
21 kg•m
(152 ft lb)

18. SP001523
Page 13
Track Assembly
Track Spring
d
L
L0
L
O.D
P.C.D
I.D 1
HKA1503L
Figure 11
Designation Units Dimensions
No. of Active Coils ea. 7.5
Total No. of Coils ea. 9
Spring Constant
kg/mm
(lb/0.0394 in)
23.03
(50.77)
Set Load
kg
(lb)
875
(1929)
Compressive Load
kg
(lb)
4650
(10,250)
Minimum Closed Length (L)
mm
(in)
195.1
(7.68)
Free Length (L0)
mm
(in)
261
(10.28)
Set Length (L1)
mm
(in)
233.5
(9.19)
Outside Diameter
mm
(in)
78
(3.07)
Mean Diameter
mm
(in)
63
(2.48)
Inside Diameter
mm
(in)
48
(1.89)
Wire Diameter (D)
mm
(in)
15
(0.59)

19. SP001523Track Assembly
Page 14
Sprocket
A
B
C
D
E
HKA1702L
Figure 12
No Item Unit Standard Limits Remarks
A Sprocket Tooth Width
mm
(in)
22.0
(0.87)
16.0
(0.63)
Rebuild or Replace
B Sprocket Deddendum Diameter
mm
(in)
ø253.0
(9.96)
ø240.0
(9.45)
Rebuild or Replace
C Mounting Bolt Tightening Torque
kg•m
(ft lb)
6.5
(47)
M10
D Motor Mounting Bolt Tightening Torque
kg•m
(ft lb)
6.5
(47)
M10 x 1.5
E Travel Motor Mounting Hole
mm
(in)
ø140.0 mm
(5.51 in)
-

20. SP001523
Page 15
Track Assembly
TRACK SHOES AND LINKS
Track Removal
1. Position machine on a smooth level surface with adequate
room for forward and reverse travel.
2. Relieve track tension. Refer to "Track Tension" in this
section for procedure.
3. Swing the front attachment to the side being serviced. Lift
the side by lowering the boom to the ground. Install jack
stands to support the weight of the equipment.
Rubber Shoes
1. Loosen track tension cylinder nut and relieve all pressure
and be certain that the cylinder is completed retracted.
2. Use a steel bar for leverage and slide the rubber track
assembly over the idler assembly.
HKA1304L
Figure 13
Figure 14

21. SP001523Track Assembly
Page 16
Track Installation
Rubber Shoes
1. With upper structure at 90° to track frame. Use bucket and
boom to raise track frame off blocking.
2. Place rubber track assembly over idler and rollers.
3. Use a steel bar for leverage and slide the rubber track
assembly over the idler assembly.
4. Apply track tension. Refer to "Track Tension" in this
section for procedure.
HKA1304L
Figure 15
Figure 16

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23. SP001523
Page 17
Track Assembly
INTERCHANGING SHOE TYPES
The steel and rubber track assemblies can be interchanged as
necessary depending on the application.
Changing to Rubber Track Assembly
1. Refer to "Track Removal" section to remove the track
assembly before proceeding to the following steps.
2. Remove steel track idler.
3. Remove steel track rollers.
4. Install rubber track rollers and tighten to specified torque.
NOTE: Steel tracks use a washer (1, Figure 18).
5. Install rubber track idler.
NOTE: Nut tightening torque: 21 kg•m (152 ft lb)
6. Refer to "Track Installation" section for track assembly
installation procedures.
Changing to Steel Track Assembly
1. Refer to "Track Removal" section to remove the track
assembly before proceeding to the following steps.
2. Remove rubber track idler.
3. Remove rubber track rollers.
4. Install steel track rollers and tighten to specified torque.
5. Install steel track idler.
NOTE: Nut tightening torque: 21 kg•m (152 ft lb)
6. Refer to "Track Installation" section for track assembly
installation procedures.
Figure 17
HKA1802S
1
Figure 18

24. SP001523Track Assembly
Page 18
FRONT IDLER ROLLER
Parts List
7
7
6
6
5
5
4
4
2
1
3
8
8
HKA1401L
Figure 19
Reference
Number
Description
1 Front Idler Assembly
2 Idler
3 Shaft
4 Bearing (BL-207)
5 Retaining Ring
6 Oil Seal
7 Spring Pin
8 Guide
Reference
Number
Description

25. SP001523
Page 19
Track Assembly
Removal and Disassembly
1. Refer to "Track Removal" section to remove the track
assembly before proceeding to the following steps.
2. Remove spring pin (7, Figure 20) from guide (8).
3. Remove guide (8, Figure 20) from shaft (3).
4. Remove oil seal (6, Figure 20) using a screw driver.
NOTE: Once removed, the oil seal should not be reused.
5. Remove retaining ring (5, Figure 20), bearing (4), and shaft
(3).
6. Repeat steps 2 - 5 for other side.
Reassembly and Installation
1. Degrease, clean and dry all parts before reassembly.
2. Insert shaft (3, Figure 20) into idler gear (2).
3. Assemble bearing (4, Figure 20) onto shaft (3) and install
retaining ring (5)
4. Install new grease seal (6, Figure 20).
5. Install Shaft guide (8, Figure 20) and spring pin (7).
6. Repeat steps 1 - 5 for other side.
7. Refer to "Track Installation" section for track assembly
installation procedures.
7
6
5
4
2
3
8
HBOH850L
Figure 20