Doosan DX60R Install guide

K1042957E Shop Manual
Copyright 2008 DOOSAN
DOOSAN reserves the right to improve its products continuously, delivering the best possible product to
the marketplace. These improvements can be implemented at any time with no obligation to change
materials previously sold. It is recommended that consumers periodically contact their distributors for
most recent documentation on purchased equipment.
This documentation may include attachments and optional equipment 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
K1042957E
Serial Number 50001 and Up
DX60R



Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Safety..........................................................................SP001614
Specifications
Specification for DX60R.........................................................................SP001615
General Maintenance
General Maintenance Procedures.........................................................SP000016
Standard Torques..................................................................................SP000813
Upper Structure
Cabin .....................................................................................................SP001623
Swing Bearing .......................................................................................SP001624
Lower Structure and Chassis
Track Assembly.....................................................................................SP001625
Engine and Drive Train
Engine....................................................................................................SP001693
Drive Coupling (Main Pump) .................................................................SP001627
Hydraulics
Accumulator ..........................................................................................SP000028
Center Joint (Swivel)..............................................................................SP001628
Cylinders................................................................................................SP001629
Swing Motor...........................................................................................SP001630
Travel Motor...........................................................................................SP001686
Main Control Valve.................................................................................SP001639
Main Pump.............................................................................................SP001488

Table of Contents
Page II
Remote Control Valve (Work Lever / Joystick) ......................................SP001640
Dozer Valve ...........................................................................................SP001490
Travel Contorl Valve...............................................................................SP001641
Pedal Valve............................................................................................SP001073
Hydraulic Schematic .............................................................................SP001692
Electrical System
Electrical System ...................................................................................SP001687
Electrical Schematic (DX60R/DX80R) ...................................................SP001688
Attachments
Boom and Arm.......................................................................................SP001642
Bucket....................................................................................................SP001643

1Safety


SP001614
Track Excavator Safety
Page 2
MEMO

SP001614
Page 3
Track Excavator Safety
Table of Contents
Track Excavator Safety
Safety Precautions................................................ 5
Applicable Models ............................................... 5
To the Operator of a Excavator ............................ 6
General Safety Essentials................................... 10
Location of Safety Labels ................................... 11
Summary of Safety Precautions for Lifting in
Digging Mode..................................................... 11
Unauthorized Modifications................................ 13
General Hazard Information ............................... 13
Before Starting Engine ....................................... 22
Machine Operation............................................. 26
Maintenance....................................................... 33
Battery ................................................................ 44
Towing ................................................................ 46
Shipping and Transportation.............................. 47
Lifting With Sling................................................. 47

SP001614
Track Excavator Safety
Page 4
MEMO

SP001614
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 the load.
Remember that ultimate safety is your own responsibility.
MODEL SERIAL NUMBER RANGE
DX60R 50001 and Up

SP001614Track Excavator Safety
Page 6
TO THE OPERATOR OF A
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 1-10
2. “Location of Safety Labels” on page 1-11
3. “Summary of Safety Precautions for Lifting in Digging
Mode” on page 1-11
4. “Unauthorized Modifications” on page 1-13
5. “General Hazard Information” on page 1-13
6. “Before Starting Engine” on page 1-22
7. “Machine Operation” on page 1-26
8. “Maintenance” on page 1-33
9. “Battery” on page 1-44
10. “Towing” on page 1-46
11. “Shipping and Transportation” on page 1-47
12. “Lifting With Sling” on page 1-47
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.

SP001614
Page 7
Track Excavator Safety
WARNING
Improper operation and maintenance of this machine can be
hazardous and could result in serious injury or death.
Operator and maintenance personnel should read this
manual thoroughly before beginning operation or
maintenance.
Keep this manual in the storage compartment to the rear of
the operator's seat, and have all personnel involved in
working on the machine read the manual periodically.
Some actions involved in operation and maintenance of the
machine can cause a serious accident, if they are not done
in a manner described in this manual.
The procedures and precautions given in this manual can
be applied only to intended uses of the machine.
If you use your machine for any unintended uses that are
not specifically prohibited, you must be sure that it is safe
for any others. In no event should you or others engage in
prohibited uses or actions as described in this manual.
DOOSAN delivers machines that comply with all applicable
regulations and standards of the country to which it has
been sent. If this machine has been purchased in another
country or purchased from someone in another country, it
may lack certain safety devices and specifications that are
necessary for use in your country. If there is any question
about whether your product complies with the applicable
standards and regulations of your country, consult
DOOSAN or your DOOSAN distributor before operating the
machine.

SP001614Track Excavator Safety
Page 8
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
This word is used on safety messages and safety labels and
indicates potential threat 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
This word is used on safety messages and safety labels and
indicates potential threat of a hazardous situation that, if
not avoided, could result in serious injury or death. It may
also be used to alert against highly unsafe practice.
DANGER
This word is used on safety messages and safety labels and
indicates an 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 detonate or explode if handled or treated carelessly.

SP001614
Page 9
Track Excavator Safety
Safety precautions are described in SAFETY from page -11 on.
DOOSAN cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore the
safety messages in this manual and on the machine may not
include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual
are used, you must be sure that you and others can do such
procedures and actions safely and without damaging the
machine. If you are unsure about the safety of any procedures,
contact a DOOSAN distributor.

SP001614Track Excavator Safety
Page 10
GENERAL SAFETY ESSENTIALS
Accessory Applications
The excavator has been primarily designed for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN for proper installation and application.
Lifting-work applications (unless restricted or prohibited by
local regulations) are permitted in approved lift configuration, to
rated capacity only, with no side-loading. DO NOT use the
machine for activities for which it was not intended. DO NOT
use the bucket for lifting work, unless lift slings are used in the
approved configuration.
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.
Lifting Capacity Rating Configuration
Lifting capacity ratings that are printed at the end of this safety
section are based on the machine being level, on a firm
supporting surface, with hooks and slings attached in approved
configuration. Loads must be balanced and supported evenly.
Use tag lines to keep the load steady if wind conditions and
large surface area are a problem. Work crew hand signals,
individual tasks and safe procedures should all be universally
understood before the lift is made.
IMPORTANT
Before using the excavator to make lifts check municipal
and regional regulations or statutes that could apply.
Governing ordinances may require that all heavy lifting be
done with single purpose equipment specifically designed
for making lifts, or other local restrictions may apply.
Making heavy lifts with a general purpose excavator that
can be used for digging, loading, grading or other work may
be expressly forbidden by a regional injunction or other
legal prohibition. Always follow all the other instructions,
guidelines and restrictions for Safe Lifting in the Operation
and Maintenance Manuals.

SP001614
Page 11
Track Excavator Safety
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.
SUMMARY OF SAFETY
PRECAUTIONS FOR LIFTING IN
DIGGING MODE
To lift safely while in Digging Mode, the following items must be
evaluated by the operator and the work site crew.
• Condition of ground support.
• Excavator configuration and attachments.
• Weight, lifting height and lifting radius.
• Safe rigging of the load.
• Proper handling of the suspended load.
Tag lines on opposite sides of the load can be very helpful in
keeping a suspended load secure, if they are anchored safely
to control points on the ground.
DANGER
Unsafe use of the excavator while making rated lifts could
cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property. Do not let
anyone operate the machine unless they've been properly
trained and understand the information in the Operation
and Maintenance Manual.
WARNING
NEVER wrap a tag line around your hands or body.
NEVER rely on tag lines or make rated lifts when wind gusts
are more than 48.3 km/h (30 MPH). Be prepared for any wind
gust when working with loads that have a large surface
area.

SP001614Track Excavator Safety
Page 12
WARNING
If you need more information or have any questions or
concerns about safe operating procedures or working the
excavator correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.
This manual suits for next models
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