Part of the Doosan Repair Manuals.
Need factory answers for your 2008 Doosan DX60R track excavator? This 868-page Doosan DX60R Shop Manual PDF (OEM #K1042957E) takes the whole machine apart on paper, swing bearing to bucket pins. You get the full hydraulic schematic, a DX60R/DX80R electrical schematic mapping the charging, starting, and engine control circuits, and standard torque tables for metric and U.S. fasteners. Step-by-step teardown and rebuild procedures run through the main pump, swing motor, travel motor, main control valve, and cylinders, each backed by its own troubleshooting. Fill the hydraulic tank to 65 liters, and run 11.6 liters of API CF 10W30 in the engine. Your machine is down and the clock is running. Get factory numbers, not forum guesses. Bookmarked with a full text layer: search any spec, jump to any section, fix the excavator.
What's Inside This Doosan DX60R Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 5-52 | Track Excavator Safety (Safety Precautions, Applicable Models, To the Operator of a Excavator, Location of Safety Labels, Summary of Safety Precautions for Lifting in Digging Mode, Unauthorized Modifications, Before Starting Engine, Machine Operation, Maintenance, Battery, Towing, Shipping and Transportation, Lifting with Sling) |
| Specifications | 53-78 | Overall Dimensions, Working Range, Standard Specifications, Engine Performance Curves, Performance Tests, Applicable Models |
| General Maintenance Procedures | 79-98 | Welding Precautions, Hydraulic System Cleanliness, Maintenance Service, Bearing Inspection, Cleaning and Inspection |
| Standard Torques | 99-114 | Metric Fastener Torques, U.S. Fastener Torques, Hose Clamp Torques, Torque Wrench Extension |
| Cabin | 115-126 | Tilting Procedure, Removal, Installation, Applicable Models |
| Swing Bearing | 127-134 | Axial Play Measurement, Rebuilding, Maintenance, Applicable Models |
| Track Assembly | 135-166 | Track Tension, Idler Disassembly, Lower Roller, Upper Roller, Sprocket Disassembly |
| Engine | 167-434 | General Service Information, Periodic Maintenance, Cylinder Head, Fuel System, Cooling System, Starter Motor, Alternator, Troubleshooting |
| Drive Coupling (Main Pump) | 435-442 | Drive Coupling Diagram, Installation Procedure, Applicable Models |
| Accumulator | 443-450 | Precharge Pressure, General Description, Applicable Models |
| Center Joint (Swivel) | 451-462 | Disassembly Diagram, Reassembly, Center Joint Assembly, Disassembly, Applicable Models |
| Cylinders | 463-492 | Theory of Operation, Special Tools, Assembly, Disassembly |
| Swing Motor | 493-536 | Working, Disassembly and Assembling, Maintenance Standards, Troubleshooting |
| Travel Motor | 537-610 | Operating Principle, Special Tools and Materials, General Description, Troubleshooting, Assembly, Disassembly |
| Main Control Valve | 611-658 | Composition and Function, Relief Valve, Mounting, Cleaning and Inspection, Assembly, Disassembly |
| Remote Control Valve (Work Lever / Joystick) | 713-728 | Joystick Pilot Valve: Structure and Pilot Pressure Control, Secondary Pressure Performance Curve, Spool and Spring Kit Parts List, Disassembly and Reassembly, Neutral Return Check |
| Dozer Valve | 729-744 | Dozer Blade Control Valve: Spool and Poppet Structure, Relief Setting and Blade Lift/Lower Circuit, Seal Kit Replacement, Disassembly and Reassembly |
| Travel Control Valve | 745-766 | Maintenance, Performance Specification, Troubleshooting, Assembly, Disassembly |
| Pedal Valve | 767-780 | Tools and Materials, Assembly, Disassembly |
| Hydraulic Schematic | 781-786 | DX60R Schematic, Applicable Models |
| Electrical System | 787-840 | Electrical Supply System, Engine Starting, Charging System, Instrument System, Engine Control System, Refrigerant System Repairs, Troubleshooting |
| Electrical Schematic (DX60R/DX80R) | 841-846 | DX60R/DX80R Schematic, Applicable Models |
| Boom and Arm | 847-858 | Front Attachment Pin Specifications, Start-Up Procedures, Removal, Installation, Applicable Models |
| Bucket | 859-868 | Bucket Tooth Replacement, Bucket O-Ring Replacement, Removal and Reversal, Applicable Models |
Every system also includes safety precautions.
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Standard Torques | SP000813 | p. 3 |
| Oil Capacity | 11.6 liter | p. 68 |
| Oil Grade | API class CF, SAE grade 10W30 | p. 68 |
| Hydraulic tank | 65 l | p. 66 |
| Hexagon Bolt (7T) and Nut M6 x 1.0 mm | 7 - 9 ft-lb (87 - 104 in.-lb, 9.8 - 11.8 N·m, 1.0 - 1.2 kgf·m) | p. 215 |
| Intake / Exhaust Valve Clearance | 0.006 - 0.010 in. (0.15 - 0.25 mm) | p. 213 |
| Engine Coolant Capacity | 4.2 L Engine Only | p. 212 |
| Valve Clearance | 0.006 - 0.010 in. (0.15 - 0.25 mm) | p. 213 |
| Engine Rated power (Gross) | 50.4 hp @ 2,200 rpm | p. 66 |
| Fuel tank capacity | 78 L | p. 66 |
| Hydraulic tank capacity | 65 L | p. 66 |
| Main relief set pressure | 21-23 MPa | p. 66 |
Doosan DX60R Common Problems This Manual Covers
Doosan DX60R travel motor turns slow on one side, machine pulls and slips sideways on slopes
Check the travel motor troubleshooting steps before splitting anything. Test the counterbalance valve and relief valve for sticking spools, and verify the 2-speed changeover shifts in both ranges. If you do open the motor, torque the reamer bolts to 186 ±29 ft-lb during reassembly per page 562.
Manual Section: Travel MotorSwing motor slips and loaded bucket drifts downhill during slope work, brake torque feels weak
Inspect the swing parking brake and compare brake torque against the maintenance standards in the Swing Motor section starting on page 493. Measure circuit pressure at the swing relief; low pressure with a hot system points to a worn rotary group in the 31.5 cc/rev motor. Replace friction plates if slip continues.
Manual Section: Swing Motor p. 493Boom drops slowly under load and bucket will not lower fast in an emergency
Test main relief pressure at the pump port; the setting should hold 21-23 MPa per the specifications on page 66. Work through the spool stroke and load-holding checks in the Main Control Valve section starting on page 611, then inspect the boom cylinder piston seals for internal bypass and replace any scored spools.
Manual Section: Main Control Valve p. 611Engine cranks slowly in cold weather, starts hard, then dies at idle
Verify battery voltage and clean the ground connections before condemning the starter. Check the air heater relay and glow circuit against the E-ECU failure detection list. Fill the crankcase with API CF, SAE 10W30 oil (11.6 liter capacity, page 68); heavy summer oil drags cranking speed down in the cold.
Manual Section: Electrical SystemTracks run loose, machine wanders off line, track jumps the sprocket in reverse
Measure track tension using the Track Assembly procedure starting on page 135 and adjust at the grease cylinder. Check chain wear by measuring pitch across several links; nominal link pitch is 135 mm per page 145. Inspect sprocket teeth and idler flanges for hooking, and replace worn components as a set, never new chain on a worn sprocket.
Manual Section: Track Assembly p. 135Frequently Asked Questions
How to reset DOOSAN DX60R error codes?
For most engine control unit (ECU) failure detection conditions, the recommended action for recovery is to turn the key off. This procedure is indicated for issues such as coolant temperature sensor failure, accelerator sensor failure, and rack position sensor failure, as detailed in the diagnostic list on page 91 (816/868). p. 816
What are the torque specs for DOOSAN DX60R engine bolts?
For Hexagon Bolt (7T) and Nut, an M6 x 1.0 mm bolt requires 7 - 9 ft-lb (9.8 - 11.8 N*m) of torque. For Pipe Joint Bolts, an M8 bolt requires 9 - 12 ft-lb (12.7 - 16.7 N*m) of torque. These values are for clean, non-lubricated fasteners, and 60% torque should be applied to bolts not listed, and 80% to aluminum alloy. p. 214
How to reset DOOSAN DX60R fuel alert?
The Fuel Exhausted warning light (Input Terminal 7) illuminates when the fuel is almost exhausted. To reset this alert, the machine should be refueled. The warning light will turn off once the fuel level is no longer critically low. p. 806
What is the engine oil capacity for the DOOSAN DX60R?
The engine oil capacity for the DOOSAN DX60R, specifically for a 'deep standard' oil pan, is 10.2 L (upper limit) and 5.7 L (lower limit). It is recommended to refer to the operation manual provided by the machine manufacturer for the actual engine oil capacity. p. 213
What are the intake and exhaust valve clearance specifications for the DOOSAN DX60R?
For all models of the DOOSAN DX60R, the intake and exhaust valve clearance should be between 0.006 - 0.010 inches (0.15 - 0.25 mm). This specification is crucial for maintaining engine performance and is detailed in the 'Engine Service Standards' section on page 213 (68/868). p. 213
Is this Doosan DX60R Shop Manual a digital download?
A 868-page Shop Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Can I print specific sections of this Doosan DX60R Shop Manual?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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