Part of the Doosan Repair Manuals.
Looking for a Doosan DX80R service manual PDF you can actually trust? This 864-page factory shop manual (OEM #K1044971E) tears into the DX80R Track Excavator from swing bearing to travel motor. Inside: full hydraulic schematics, a complete electrical schematic section, and step-by-step disassembly and assembly procedures for the main pump, swing motor, cylinders, main control valve, and track assembly. You also get standard torque tables for metric and U.S. fasteners, hose clamps, and split flanges. Set 1/2-inch split flange bolts to 15 to 18 ft lb, and hold lower roller press fit between 1.00 and 1.25 mm before you close up the undercarriage. Your excavator is down; forum guesses won't lift it. Bookmarked with a full text layer: download it, pull it up on your phone next to the tracks, and get back to work.
What's Inside This Doosan DX80R Manual
| System | Pages | Key Topics |
|---|---|---|
| Track Excavator Safety | 5-54 | Safety Precautions, Operator Responsibilities, Hazard Information, Maintenance Safety, Towing, Lifting |
| Specification for DX80R | 55-80 | General Description, Component Locations, General Dimensions, Working Range, Performance Tests |
| General Maintenance Procedures | 81-100 | Welding Precautions, Hydraulic System Cleanliness, Cleaning and Inspection, Bearing Inspection |
| Standard Torques | 101-116 | Metric Fasteners, U.S. Fasteners, Hose Clamps, Split Flanges, Torque Wrench Extension Tools |
| Cabin | 117-128 | Safety Precautions, Cabin Removal, Cabin Installation, Cabin Tilting |
| Swing Bearing | 129-136 | Swing Bearing Maintenance, Measuring Axial Play, Measuring Lateral Play, Rebuilding Swing Bearing |
| Track Assembly | 137-186 | Track Tension, Steel Tracks, Rubber Tracks, Idler Assembly, Lower Roller, Upper Roller, Sprocket |
| Engine | 187-454 | Engine Specifications, Periodic Maintenance, Fuel System, Cooling System, Lubrication System, Starter Motor, Alternator |
| Drive Coupling (Main Pump) | 455-462 | Drive Coupling Installation, Precaution, Installation Procedure |
| Accumulator | 463-470 | General Description, Theory of Operation, Specifications |
| Center Joint (Swivel) | 471-482 | General Description, Disassembly, Reassembly, Center Joint Assembly |
| Cylinders | 483-514 | Theory of Operation, Arm Cylinder, Bucket Cylinder, Boom Swing Cylinder, Dozer Cylinder, Special Tools |
| Swing Motor | 515-568 | Swash Plate Motor, Relief Valve, Makeup Valve, Planetary Reduction Gear, Troubleshooting |
| Travel Motor | 569-636 | Operating Principle, Disassembly, Assembly, Performance Confirmation Test |
| Main Control Valve | 637-656 | Functional Description, Sx 14 Control Block, Inlet/Outlet Elements, Hydraulic Operator Removal |
| Main Pump | 657-710 | A10V(S)O Pressure/Flow Control, Spare Parts Kits, Control Valve Dfr, Taper Roller Bearing Adjustment |
| Remote Control Valve (Work Lever / Joystick) | 711-726 | Performance Specification, Disassembly Method, Assembly Method |
| Travel Control Valve | 727-748 | Performance Specification, Maintenance Standard, Disassembly, Assembly, Troubleshooting |
| Dozer Valve | 749-762 | Structure Diagram, Performance Specification, Hydraulic Pressure Circuit Diagram, Disassembly and Assembly Tools, Disassembly, Assembly Method |
| Pedal Valve | 763-776 | General Description, Tools and Materials, Disassembly, Assembly, Applicable Models and Safety Precautions |
| Hydraulic Schematic | 777-782 | Safety Precautions, Applicable Models, DX80R |
| Electrical System | 783-842 | Electrical Supply System, Engine Starting, Instrument System, Refrigerant System, Electrical Schematic |
| Boom and Arm | 843-854 | Front Attachment Pin Specifications, Arm Removal, Boom Removal, Installation |
| Bucket | 855-864 | Bucket Tooth Replacement, Bucket O-Ring Replacement, Detaching/Attaching Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Standard Torque for 1/4" - 20 (Grade 5) | 6 ft lb (8 Nm) | p. 108 |
| Standard Torque for 2" - 4 1/2 (Grade 8) | 5760 ft lb (7810 Nm) | p. 108 |
| Lower Roller Steel Track Clearance Amount | 0.70 ~ 1.06 mm | p. 154 |
| Lower Roller Steel Track Press Fit Amount | 1.00 ~ 1.25 mm | p. 153 |
| Idler Steel Track Clearance Shaft Dim | 50 mm | p. 151 |
| Idler Steel Track Clearance Bushing Dim | 50 mm | p. 151 |
| Steel Track Pin Clearance Standard | 0.29 mm | p. 148 |
| Steel Track Pin Clearance Limit | 2.0 mm | p. 148 |
| Engine Rated Power | 40.7 kW @ 2,000 rpm | p. 68 |
| Main Relief Set Pressure | 280 kg/cm2 | p. 68 |
| Fuel Tank Capacity | 110 liters | p. 68 |
| Hydraulic Tank Capacity | 87 liters | p. 68 |
Doosan DX80R Common Problems This Manual Covers
Doosan DX80R one track weak or stops completely under load after hydraulic oil warms up
Run the travel motor performance confirmation test in the travel motor section starting on page 569. Check main relief pressure against the 280 kg/cm2 spec on page 68. Inspect the center joint seals for internal leakage, then drain and refill each final drive with 1.5 liters of gear oil per page 634.
Manual Section: Travel Motor p. 569Engine cranks slowly or won't start, clicking from the starter relay in cold weather
Check battery voltage and load-test it before condemning the starter. Clean and tighten both ground straps at the frame. Trace the starting circuit on the wiring diagram on page 71, then work through the electrical system section from page 783. After start, verify the engine reaches its rated 2,000 rpm listed on page 68.
Manual Section: Electrical System p. 783Coolant temperature climbs and power drops off during hard digging or long travel runs
Blow out the radiator, oil cooler, and condenser cores from the fan side with compressed air. Check coolant and hydraulic oil levels; the hydraulic tank holds 87 liters per page 68. Retorque radiator hose T-bolt clamps to 0.68 to 0.72 kg-m (59 to 63 in lb) per page 110, and inspect fan belt tension.
Manual Section: Engine p. 187All hydraulic functions slow and weak, bucket stalls before reaching full breakout force
Verify main relief pressure at the pump test port against the 280 kg/cm2 setting on page 68. Replace the return filter and confirm tank level; the system holds 87 liters. If pressure stays low, follow the main pump section starting on page 657 and inspect the A10VO regulator and rotating group for wear.
Manual Section: Main Pump p. 657Tracks derail, squeal, or show rapid pin and bushing wear on steel undercarriage
Measure track pin clearance and replace pins past the 2.0 mm wear limit on page 148; check bushing thickness against the 39.5 mm limit on the same page. Adjust track tension per the track assembly section starting on page 137, then retorque sprocket mounting bolts to 18 kg-m (130 ft lb) listed on page 158.
Manual Section: Track Assembly p. 137Frequently Asked Questions
What is the torque specification for the Doosan DX80R track roller mounting bolts?
The bolt tightening torque for the track rollers on the DX80R is 14 kg·m (101.26 ft lb). p. 177
What is the replacement interval for the fuel filter on the DX80R engine?
The fuel filter should be replaced every 500 hours of operation. After the initial change at 50 hours, replace the fuel filter at the same time as the engine oil filter. p. 269
What is the correct tightening torque for the cylinder head bolts on the engine?
The cylinder head bolts must be tightened in two steps. The first step is 1/2 of the final torque, and the second step is the final torque of 76 - 83 ft·lb (103.1 - 112.9 N·m; 8.7 - 9.3 kgf·m). p. 287
What is the standard intake and exhaust valve clearance for the engine?
The standard intake and exhaust valve clearance for the engine is 0.006 - 0.010 in. (0.15 - 0.25 mm). p. 281
What is the required oil capacity for the engine oil pan?
The engine oil pan capacity is 10.2 liters for the upper limit and 5.7 liters for the lower limit. p. 232
Is this Doosan DX80R manual a PDF I download?
All 864 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Can I print just the pages I need from this Doosan DX80R manual?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
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