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1. Original InstructionsCopyright DOOSAN 2014
Serial Number 1001 and Up
Serial Number 50001 and Up
Shop Manual
DX300LC-5 Excavator
950106-00980E
February 2014
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

2. Table of Contents
Page I
1Table of Contents
1 Safety 1 Track Excavator Maintenance Safety
2 Specifications 1 Specifications
3 General Maintenance 1 General Maintenance Instructions
2 Standard Torques
4 Engine 1 Engine
2 Engine Coolant Heater (Option)
5 Upper Structure 1 Cabin
2 Counterweight
3 Oil Tank
4 Fuel Tank
5 Main Pump
6 Drive Coupling (Main Pump)
7 Main Control Valve
8 Swing Device
9 Fan Pump for Oil Cooler
10 Fan Motor for Oil Cooler
11 Gear Pump (Rotation)
12 Joystick Valve (Work Lever)
13 Travel Control Valve (with Damper)
14 Solenoid Valve
15 EPPR Valve
16 Accumulator
6 Lower Structure and Chassis 1 Swing Bearing
2 Center Joint
3 Travel Device
4 Track Assembly

3. Table of Contents
Page II
7 Front 1 Boom and Arm
2 Bucket
3 Cylinders
8 Hydraulic System 1 Hydraulic System
2 Hydraulic System Testing and Adjustment
3 Hydraulic System Troubleshooting
9 Electrical System 1 Electrical System
2 Electrical System Troubleshooting
10 Options 1 One Way
2 Two-way
3 Rotating
4 Quick Coupler
5 Two Pump
11 Schematic 1 Hydraulic Schematic/Electrical Schematic

4. Track Excavator Maintenance Safety
1-1-1
DX300LC-5
Track Excavator
Maintenance
Safety
Edition 1

5. Track Excavator Maintenance Safety
1-1-5
DX300LC-5
SAFETY INSTRUCTIONS
SAFETY MESSAGES
Replace with Safety Messages Section on pages III and IV in
the Doosan Operation & Maintenance Manual.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.

6. DX300LC-5Track Excavator Maintenance Safety
1-1-6
GENERAL
Safe Operation is Operator's
Responsibility
Only trained and authorized personnel should operate and
maintain the machine.
Follow all safety rules, regulations and instructions when
operating or performing maintenance on machine.
• Do not operate machine if you are under the influence of
drugs or alcohol. An operator who is taking prescription
drugs must get medical advice to determine if he or she
can safely operate a machine.
• When working with other personnel on a work site, be sure
that all personnel know nature of work and understand all
hand signals that are to be used.
• Be sure that all guards and shields are installed in their
proper location. Have guards and shields repaired or
replaced immediately if damaged.
• Be sure that you understand the use and maintenance of
all safety features such as safety lever and seat belt. Use
them properly.
• Never remove, modify or disable any safety features.
Always keep them in good operating condition.
• Always check for and know the location of underground
and overhead utility lines before excavating.
• Failure to use and maintain safety features according to
instructions in this manual, Safety Manual and Shop
Manual can result in death or serious injury.
Know Your Machine
Know how to operate your machine. Know the purpose of all
controls, gauges, signals, indicators and monitor displays. Know
the rated load capacity, speed range, braking and steering
characteristics, turning radius and operating clearances. Keep in
mind that rain, snow, ice, loose gravel, soft ground, slopes etc.,
can change operating capabilities of your machine.

7. Track Excavator Maintenance Safety
1-1-7
DX300LC-5
Proper Work Tools and Attachments
Only use work tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When installing and
using optional attachments, read instruction manual for
attachment, and general information related to attachments in this
manual. Because DOOSAN cannot anticipate, identify or test all
attachments that owners may want to install on their machines,
contact DOOSAN for written authorization and approval of
attachments, and their compatibility with optional kits.
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or combination of work
equipment, there is a potential that work equipment could
interfere with the cabin or other parts of machine. Before using
unfamiliar work equipment, check if there is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary hydraulic kits
for attachments installation. If you are in doubt about
compatibility of a particular attachment with a machine, consult
your DOOSAN distributor.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure
to do so can result in death or serious injury.
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.
FG018457
Figure 1

8. DX300LC-5Track Excavator Maintenance Safety
1-1-8
High-pressure oil that is released can cause a hose to whip or oil
to spray. Fluid penetration can result in death or serious injury. If
fluid enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Obey all local laws and regulations for disposal of liquids.
To prevent hot coolant from spraying out, stop engine and wait
for coolant to cool. Using gloves, slowly loosen cap to relieve
pressure.
Flying or Falling Objects
On work sites where there is a potential hazard that flying or
falling objects can hit operator's cabin, select and use a guard to
match operating conditions for additional operator protection.
Working in mines, tunnels, deep pits, and loose or wet surfaces,
could produce hazard of falling rocks or flying objects. Additional
protection for operator's cabin could be required such as an
Operator Protection Guard (OPG) or window guards. Contact
your DOOSAN distributor for information on available protective
guards.
To prevent personnel from being struck by flying objects, keep
personnel out of work area.
HAOA110L
Figure 2
HAOA100L
Figure 3

9. DX300LC-5Engine
4-1-1
Engine
Edition 1

10. Engine
4-1-7
DX300LC-5
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.

11. DX300LC-5Engine
4-1-8
OVERVIEW
EX1301800
FRONT
Figure 1

12. Engine
4-1-51
DX300LC-5
Replacing the Engine
NOTE: Replace coolant hoses if there is clear damage to the
coolant hoses.
1. Drain the oil and coolant.
2. Remove air filter and inlet pipe between the turbocharger
and air filter. Cover the turbocharger inlet pipe.
3. Undo the connections for coolant, charge air pipes
between engine and charge air cooler, and bleed pipe for
the expansion tank.
4. Undo the cable harness with clamping.
NOTE: The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
5. Fasten the lifting chain 98 094 to the rear lifting eyes 99
637.
6. Fasten the lever block 587 308 to the front lifting eye.
NOTE: The lifting eyes 99 637 are designed to manage
a maximum inclination angle of 30° when lifting
an engine.
7. Undo the engine insulator bolts and lift away/out the
engine.
• Engine weight: about 950 kg
FG020236
Figure 20
FG020237
max 30
max 20
Figure 21

13. DX300LC-5Engine
4-1-52
Removal of Engine
1. Depressurize the fuel system using checking tool.
2. Disconnect the ground connection from the negative
terminal and disconnect the cable harness from the starter
motor.
NOTE: Help protect the environment. Avoid spillage
and use a suitable container.
3. Drain the coolant.
4. Undo the connections for coolant, charge air pipes
between engine and charge air cooler, and bleed pipe for
the expansion tank.
5. Remove air filter and inlet pipe between the turbocharger
and air filter. Cover the turbocharger inlet pipe.
6. Disconnect the fuel pipes to and from the engine. Mark the
pipes to make reinstalling easier and plug the connections.
7. Remove coolant connections for SCR, to engine (1) and
from engine (2).
IMPORTANT
The fuel system has a very high fuel pressure of up to
3,000 bars. The fuel system must be depressurized
using checking tool before any work is started.
Use checking tool to minimize the high-pressure in the
fuel system.
The system should always be treated as pressurized,
even when the engine is switched off.
Wear protective gloves and goggles.
EX1301906
2
1
Figure22

14. Engine
4-1-53
DX300LC-5
8. Disconnect connectors C4001 (1) and C4002 (3) and
connector C4022 (4) to SCR.
• To be removed depending on the installation:
• Unit gearbox.
• Coolant level sensor.
• Protective casing on cooling package and fan.
• Depressurize the pneumatic system and remove
connections.
• Power take-off, see subgroup 01-55 Power take-off.
• Hydraulic pump, see subgroup 13-15 Hydraulic
pump.
• Disconnect the AC compressor and place it to one
side.
9. Fasten the lifting chain 98 094 to the rear lifting eyes 99
637.
NOTE: The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high-voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
10. Fasten the ratchet lever hoist 587 308 to the front lifting
eye.
NOTE: The lifting eyes 99 637 are designed to manage
a maximum inclination angle of 30° when lifting
an engine.
11. Check carefully there is nothing that may be removed with
the engine or prevent lifting.
12. Undo the engine insulator screws and lift away/out the
engine.
1
2
3
4
EX1301907
Figure 23

15. DX300LC-5Engine
4-1-54
Installing the Engine
1. Fasten the lifting chain 98 094 to the rear lifting eyes.
NOTE: The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high-voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
2. Fasten the ratchet lever hoist 587 308 to the front lifting
eye.
3. Lift the engine, position it on the engine insulators and
screw it into place.
• If removed, reinstall:
• Unit gearbox.
• Coolant level sensor.
• Protective casing on cooling package and fan.
• Pneumatic system.
• Power take-off, see subgroup 01-55 Power take-off.
• Hydraulic pump, see subgroup 13-15 Hydraulic
pump.
• AC compressor, see subgroup 18-75 AC
compressor.
FG020236
Figure 24
EX1301876
max 30
Figure 25

16. Engine
4-1-55
DX300LC-5
4. Connect connectors C4001 (1) and C4002 (3) and
connector C4022 (4) to SCR.
5. Install the coolant connections for SCR, to engine (1) and
from engine (2).
6. Connect the fuel pipes to the high-pressure pump and
hand pump.
7. Install the inlet pipe between the turbocharger and the air
filter.
8. Install the connections for coolant and the charge air pipes
between the engine and charge air cooler. Install the
expansion tank bleed pipe.
9. Fill with coolant.
10. Install the cable harness to the starter motor and the
ground connection to the negative terminal.
11. Start checking tool and check whether there are any fault
codes. Rectify the fault codes.
12. Clear inactive fault codes.
13. Test run the engine to check that no leakage occurs. Top
up with coolant if necessary.
1
2
3
4
EX1301907
Figure 26
EX1301906
2
1
Figure27

17. DX300LC-5Engine
4-1-56
CYLINDER
Cylinder Head
Specifications
• Remove cylinder head according to the work description
°×Removal Cylinder Head°± on page 4-1-57.
• Remove inlet and exhaust valves according to the work
description °×Removing Valves°± on page 4-1-75.
Overview
Intake Valve
Oversize Valve Seat, Outer Diameter 46.254 - 46.265 mm
Valve Seat Position, Outer Diameter 46.200 - 46.216 mm
Valve Seat Position, Deep 11.25 - 11.35 mm
Exhaust Valve Seat
Oversize Valve Seat, Outer Diameter 44.281 - 44.292 mm
Valve Seat Position, Outer Diameter 44.200 - 44.216 mm
Valve Seat Position, Deep 11.25 - 11.35 mm
21
8
20
19
18
16
17
11
1D
1A
1B
1D
11
13
14
19
8
20
24
31A
31B 23
22
1: 1A ~ 1F
25C
25
31C
31C
31
36
1B
9
1C
9
10
1E
12
1F
15
25C
25A
25B
30
EX1302147Figure 28

18. Engine
4-1-57
DX300LC-5
Removal Cylinder Head
1. Remove water-cooled EGR cooler as instructed in the
work description °×Removing the EGR Cooler°± on
page 4-1-274.
Remove brackets for the water-cooled EGR cooler.
2. Remove bolts for the exhaust manifold on the relevant
cylinder and slacken the bolts on the adjacent cylinders so
the relevant part of the exhaust manifold comes loose.
3. Remove cooling system bleeder hose, separate the quick
release coupling at the front lifting eye.
4. Remove cable duct from the intake.
5. Remove cable ties for the cable harness from the engine
control unit.
IMPORTANT
The fuel system components are extremely sensitive
to dirt. Clean thoroughly before dismantling and plug
all connections with lint-free rags and tape.
Reference
Number
Description
1 Cylinder Head
1A Sleeve
1B Core Plug
1C Rivet
1D Guide Valve
1E Seal
1F Seal
8 Pin
9 Valve Stem Seal
10 Intake Valve
11 Intake Valve Spring
12 Collar Valve Spring
13 Exhaust Valve
14 Outer Valve Spring
15 Inner Valve Spring
16 Collar Valve Spring
17 Collet Valve Spring
18 Pin
19 Gasket
20 Bridge Valve
21 Screw
22 Bracket Assembly
23 Rivet Plug
24 Screw
25 Intake Rocker Arm
26 Adjusting Screw
27 Hex Nut
29 Rivet Plug
30 Retaining Ring
31 Exhaust Arm Rocker
32 Adjusting Screw
33 Hex Nut
35 Rivet Plug
36 Retaining Ring
Reference
Number
Description

19. DX300LC-5Engine
4-1-58
6. Depressurize the fuel system and detach the fuel pipe
running between the accumulator and fuel manifold.
7. Detach the fuel manifold and remove bolts on the relevant
cylinder.
8. Detach the intake manifold and remove bolts on the
relevant cylinder.
9. Remove injectors as instructed in the work description
°×Removing Injector°± on page 4-1-318.
Also remove high-pressure pipes and connection on the
cylinder head at the back viewed from the coolant pump.
10. Remove upper rocker cover and then the rocker arm
housing, valve bridges and pushrods.
11. Pull the cable harness out of the lower rocker cover and
remove it.
NOTE: Take care when pulling the cable harness out of
the rocker cover: the cable terminals can be
damaged which can cause the nut securing the
cable harness to the injector to come loose.
12. Work on the adjacent cylinders. Remove upper rocker
cover, release the cable harness and the lower rocker
cover so it can be moved.
13. Remove relevant cylinder head. Be careful with the
adjacent rocker covers.
897
FG020250
Figure 29
IMPORTANT
All parts in the fuel injection system and valve
mechanism must be marked.
Everything must be reinstalled in the same position.
IMPORTANT
If work is done on the 5th cylinder of an engine with an
EGR system, the EGR valve control cylinder must be
detached at the damper and removed.
FG020251
Figure 30
FG020252
Figure 31

20. Engine
4-1-59
DX300LC-5
NOTE: Mark the cylinder heads if more than one is
being removed at the same time.
NOTE: If all cylinder heads are removed at the same
time, the turbocharger must be removed or
supported against the frame.
Installing Cylinder Head
1. Check the liner height.
2. Clean the cylinder head and cylinder block. Lubricate the
threads and below the heads of the cylinder head bolts.
3. Install a new cylinder head gasket.
4. Install the cylinder head.
5. Tighten the cylinder head as shown in the illustration and
according to specification.
Cylinder head bolts can only be reused three times. Make
a mark with a center punch on the head of the bolt. If any of
the bolts already has three marks, it must be replaced.
6. Tighten the intake manifold. Use a new gasket. Tighten the
bolts in the order 1 - 20 as illustrated. Tighten the bolts in
the same order again.
1
2
3
4
5
6
FG020253
Figure 32
FG020254
1 2 3 4
Figure 33
1 3 5 7 9 11 13 15 17 19
2 4 6 8 10 12 14 16 18 20
FG020255
Figure 34

21. DX300LC-5Engine
4-1-60
7. Tighten the intake manifold and the exhaust manifold. Use
new gaskets.
8. Install the cable bracket bolt in the lower rocker cover and
install the following parts:
• Lower rocker cover.
• Pushrods.
• Valve bridge.
• Rocker arm housing.
9. Install the injector, high-pressure pipe connection and
high-pressure pipe as instructed in the work description.
10. Reset adjacent cylinders.
11. Adjust the valve clearance.
12. Install the upper rocker covers.
13. Install the cooling system vent
Install the brackets for the water-cooled EGR cooler.
Install the water-cooled EGR cooler as described in the
work description °×Installing the EGR Cooler°± on page 4-
1-275.
Removing and Installing Valves
1. Removing Valves
A. Remove split collets, valve spring collars, springs and
valves. Press down the spring using tool 99 322 in a
press so the collets can be removed.
B. Place the valves in a stand so they can be reinstalled
in the same position in the cylinder head.
IMPORTANT
Lubricate the valve bridge and rocker arm housing
with engine oil.
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear protective goggles for eye protection.
99 322
FG020258
Figure 35

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23. Engine
4-1-61
DX300LC-5
2. Installing Valves
NOTE: There are different versions of the combination
valve – valve spring collar – split collet. Parts
from the different versions must not be mixed
on the same valve.
A. Lubricate all parts well with engine oil before
assembly.
B. Insert the valve in the guide.
C. Install the valve springs and the valve spring collar.
D. Press together the springs in a press with tool 99 322
and install the collets. Ensure that collets are installed
in their correct positions.
Replacing a Valve Stem Seal
1. Remove valve according to the work description
°×Removing Valves°± on page 4-1-75.
2. Remove valve stem seal with a pair of pliers.
3. Install the valve.
4. Carefully tap a new valve stem seal into place using tool 99
323 and a hammer.
FG020259
99 322
Figure 36
FG020261
Figure 37
99 323
FG020262
Figure 38

24. DX300LC-5Engine
4-1-62
Replacing the Valve Seats
1. Remove valve seat inserts with an expanding sleeve from
the kit with puller 587 270 (1, Figure 39).
NOTE: Insert, for example, an aluminum sheet
between the cylinder head and counterhold to
protect against damage.
2. Press in new valve seat inserts. Use drift 99 384 (2, Figure
39) and shank 99 385. Cool the drift and valve seat insert
to about -80°C with dry ice or liquid air. Pressing must be
done rapidly.
Oversize valve seat inserts can be installed if the valve
seat insert position has been damaged.
The position is then machined using tool 587 277.
Replacing the Valve Guides
1. Press out the valve guides using drift 99 383.
2
1
FG020266
Figure 39
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear protective goggles for eye protection from flying
metal parts.
99 385
99 384
FG020267
Figure40
WARNING
AVOID DEATH OR SERIOUS INJURY
Prevent frost injuries. Be careful when handling very
cold parts and refrigerant.
99 383
FG020268
Figure 41

25. Engine
4-1-63
DX300LC-5
2. Press in the new valve guides using drift 99 382. Press the
guide down as far as the drift allows, i.e. until it contacts
the spring seat in the cylinder head.
Replacing the Injector Sleeves
The cylinder head must be removed when replacing the unit
injector sleeve. The valves do not need removing. The
illustrations show the cylinder head with valves removed to
demonstrate clearly the work described.
NOTE: Guide and pilot tap on extension piece 99 397.
1. Thread the lower part of the sleeve using the pilot tap and
guide from tool kit 99 574.
2. Knock out the pilot tap and sleeve from underneath. Use a
100 mm long metal rod of diameter 9 mm.
3. Degrease and check the contact surfaces of the sleeve
and cylinder head. Smooth off any burrs and irregularities
that may score the sleeve.
4. Degrease the new injector sleeve and apply a thin film of
sealant 561 200 on the sleeve and cylinder head contact
surfaces.
5. Press in the sleeve using the drift and guide from tool kit 99
574.
99 382
FG020269
Figure 42
FG020272
Figure 43
FG020273
Figure 44