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 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 |
