Doosan DX60R - Page 2

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Table of Contents

Table of Contents11
- Safety Precautions13
- Applicable Models13
- To the Operator of a Excavator14
- General Safety Essentials18
- Location of Safety Labels19
- Summary of Safety Precautions for Lifting in Digging Mode19
- Unauthorized Modifications21
- General Hazard Information21
- Before Starting Engine30
- Machine Operation34
- Maintenance41
- Battery52
- Towing54
- Lifting with Sling55
- Shipping and Transportation55
Table of Contents61
- Overall Dimensions68
- Working Range70
- Standard Specifications72
- Engine Performance Curves73
- Approximate Weight of Workload Materials76
- Performance Tests78
- Excavator Performance Standards79
- Test Conditions79
- Travel Speed and Travel Motor Balance (Steering Deviation) Tests79
- Swing Speed and Deceleration Force Test81
- Cylinder Performance Tests82
Table of Contents89
- Applicable Models91
- General Maintenance Procedures91
- Safety Precautions91
- Welding Precautions and Guidelines92
- Hydraulic System - General Precautions94
- General Precautions96
- Maintenance Service and Repair Procedure96
- Hydraulic System Cleanliness and Oil Leaks97
- Maintenance Precautions for Hydraulic System Service97
- Oil Leakage Precautions98
- Cleaning and Inspection99
- General Guidelines99
- Bearing Inspection100
Table of Contents109
- Applicable Models111
- Safety Precautions111
- Standard Torques111
- Torque Values for Standard Metric Fasteners112
- Torque Values for Standard U.S. Fasteners113
- Type 8 Phosphate Coated Hardware115
- Torque Values for Hose Clamps116
- Torque Values for Split Flanges116
- Torque Multiplication117
- Torque Wrench Extension Tools117
- Other Uses for Torque Wrench Extension Tools118
- Tightening Torque Specifications (Metric)119
Table of Contents127
- Applicable Models129
- Safety Precautions129
- Removal130
- Installation134
Table of Contents139
- Applicable Models141
- Safety Precautions141
- Swing Bearing141
- Measuring Bearing Lateral Play142
- Measuring Swing Bearing Axial Play142
- Operating Recommendation142
- Swing Bearing Maintenance142
- Rebuilding Swing Bearing143
- Swing Bearing Basic Operation143
Table of Contents149
- Applicable Models151
- Safety Precautions151
- Track Assembly151
- Specification and Construction152
- Tracks152
- Track Tension153
- Cleaning and Inspection (Wear Limits and Tolerances)155
- Rubber Track Features155
- Steel Tracks157
- Track Frame Spring158
- Idler159
- Steel Tracks159
- Spring Specifications160
- Lower Roller161
- Steel Track161
- Rubber Track162
- Upper Roller163
- Sprocket164
- Track Removal165
- Track Removal and Installation165
- Track Installation166
- Replacement of Rubber Tracks with Steel Tracks167
- Replacement of Steel Tracks with Rubber Tracks168
- Idler169
- Disassembly170
- Reassembly170
- Parts List171
- Track Tension Adjusting Cylinder171
- Disassembly172
- Reassembly172
Table of Contents183
- Applicable Models187
- Safety Precautions187
- Safety188
- Safety Precautions188
- Component Identification211
- General Service Information211
- Location of Labels212
- Function of Major Engine Components213
- Main Electronic Control Components and Features214
- Function of Cooling System Components216
- Diesel Fuel217
- Engine Oil221
- Engine Coolant223
- Principal Engine Specifications226
- Engine Service Standards227
- Tightening Torques for Standard Bolts and Nuts228
- Before You Begin Servicing230
- Periodic Maintenance230
- Introduction244
- Periodic Maintenance Schedule245
- Periodic Maintenance Procedures247
- Before You Begin Servicing272
- Engine272
- Cylinder Head Specifications275
- Introduction275
- Camshaft and Timing Gear Train Specifications277
- Crankshaft and Piston Specifications278
- Cylinder Block Specifications280
- Special Torque Chart281
- Special Service Tools282
- Measuring Instruments284
- 4-Valve Cylinder Head286
- Measuring and Adjusting Valve Clearance303
- Crankshaft and Camshaft Components308
- EGR System340
- Before You Begin Servicing347
- Fuel System347
- Introduction350
- Fuel System Specifications354
- Special Service Tools354
- Measuring Instruments355
- Fuel System Diagram356
- Fuel System Components358
- Fuel Injection Pump360
- Checking and Adjusting Fuel Injection Timing369
- Fuel Injectors374
- Before You Begin Servicing380
- Cooling System380
- Cooling System Diagram383
- Introduction383
- Engine Coolant Pump Components384
- Engine Coolant Pump385
- Engine Coolant System Check385
- Before You Begin Servicing390
- Lubrication System390
- Introduction392
- Oil Pump Service Information392
- Lubrication System Diagram393
- Checking Engine Oil Pressure394
- Trochoid Oil Pump394
- Before You Begin Servicing398
- Starter Motor398
- Introduction400
- Starter Motor Specifications400
- Starter Motor Troubleshooting401
- Starter Motor Components402
Table of Contents457
- Applicable Models459
- Drive Coupling (Main Pump)459
- Safety Precautions459
- Drive Coupling460
- Installation of Drive Coupling461
- Installation Procedure461
Table of Contents467
- Applicable Models469
- Safety Precautions469
- General Description470
- Specifications472
Table of Contents475
- Applicable Models477
- Center Joint (Swivel)477
- Safety Precautions477
- Disassembly Diagram478
- General Description478
- Disassembly479
- Reassembly481
Table of Contents487
- Applicable Models489
- Safety Precautions489
- General Description490
- Theory of Operation490
- Parts List492
- Piston Nut500
- Special Tools and Materials500
- Piston Jig501
- Steel Bushing Jig502
- Dust Wiper Jig503
- Slipper Seal Jig504
- Slipper Seal Straightening Jig505
- Disassembly506
- Assembly512
Table of Contents517
- Applicable Models519
- Safety Precautions519
- Swing Motor519
- Indication of Type520
- Specifications521
- Construction522
- Construction and Principles of Working522
- Principles of Working524
- External Load of Shaft528
- Inspection528
- Precaution in Use528
- Rotation Direction528
- Hydraulic Fluids and Range of Temperature529
- Filter530
- Installation and Piping530
- Oil Filling531
- Precaution in Starting Operations531
- General Cautions532
- Investigation Manner of the Motor Body532
- Troubleshooting532
- Condition and Countermeasures of Troubles533
- Disassembling and Assembling535
- Necessary Tools535
- Tightening Torque of Bolts535
- Disassembly of Motor537
- Assembly of Motor542
- Disassembly of Reduction Gear548
- Assembly of Reduction Gear551
- Maintenance Standards555
- Part Replacement Standards for Hydraulic Motor555
- Part Replacement Standards for Reduction Gear556
- Standard for Correcting Sliding Surfaces557
Table of Contents561
- Travel Motor563
- Applicable Models564
- Safety Precautions564
- Configuration565
- Features565
- General565
- Structural Diagram of the Travelling System566
- Structural Diagram of the Axial Piston Motor567
- Operating Principle568
- When Travelling568
- When Counterbalance Operates569
- When Brake Functions570
- Operating Principle of Parking Brake571
- Speed Limiting Function572
- Hydraulic Motor574
- Parts List574
- Reduction Gear576
- Special Tools and Materials578
- Standard Tools578
- Equipment and Materials579
- Measuring Devices579
- Manufacturing Tools580
- Tightening Torque584
- Weight Table584
- Counterbalance Valve585
- Travel Motor585
- Travel Motor Troubleshooting585
- 2-Speed Change over586
- Parking Brake586
- Relief Valve586
- Disassembly587
- General Suggestions When Working587
- Preparations587
- Disassembly Procedure588
- Seals607
- Service Preparations607
- Service Standards for Parts Subject to Wear607
- Assembly609
- General Suggestions When Working609
- Preparation609
- Assembly Procedure610
- Performance Confirmation Test630
- Clearance Adjustment Part Dimensions631
Table of Contents635
- Applicable Models637
- Main Control Valve637
- Safety Precautions637
- Composition, Function and Operation638
- Function of Control Valve638
- Operation of Main Section639
- Disassembly641
- Disassembly of Accessory641
- Disassembly of Arm2, Bucket, Right Run, Left Run, Arm1, Dozer, Swing, Boom Swing Section641
- Disassembly of Boom1 Section (Figure 30)642
- Disassembly of Boom2/Aux Section (Figure 35)642
- Disassembly of Inlet Section (Figure 32)642
- Disassembly of Straight Travel Section (Figure 39)642
- Take off of Load Check Poppet Type643
- Disassembly of Valve Housing644
- Cleaning645
- Inspection645
- Assembly646
- Assembly of Valve Housing646
- Assembly of Arm2, Bucket, Right Run, Left Run, Arm1, Dozer, Swing, Boom2/Aux, Boom Swing647
- Assembly of Boom1 Section (Figure 30)647
- Assembly of Boom2/Aux Section (Figure 35)647
- Assembly of Inlet Section (Figure 32)647
- Assembly of Straight Travel (Figure 39)647
- Inserting of Load Check648
- Accessory Adherence649
- Main Relief Valve (P1, P2, P3)650
- Relief Valve650
- Overload Relief Valve652
- Pressure Adjustment of Relief Valve654
- Mounting656
- Operation656
- SPEC of Control Valve656
- Failure and Troubleshooting657
- Overall Control Valve657
- Overall Pneumatic System658
- Relief Valve658
Table of Contents683
- Applicable Models685
- Main Pump685
- Safety Precautions685
- General Description686
- Description of Ports687
- Components of the Pump688
- Operation Principle and Function of Components688
- Operation Principle691
- Adjustment695
- Driving695
- Hydraulic Oil695
- Installation695
- Procedures for Test Operation696
- Maintenance and Protection697
- Checking Filters698
- Filter Replacement698
- Hydraulic Fluid Leakage Check699
- Replacement of Hydraulic Oil699
- Diagnosis of Troubles and Actions to be Taken700
- Diagnosis of Troubles with the Pump700
- Solenoid Valve and Relief Valve701
- Disassembling and Reassembling Hydraulic Pump702
- Necessary Tools and Jigs702
- Reminders for Disassembly and Assembly703
- Disassembling Procedure704
- Standard Values for Maintenance715
- Reassembly Procedure717
Remote Control Valve (Work Lever / Joystick)/Remote Control Valve (Work Lever / Joystick)737
- Applicable Models739
- Remote Control Valve (Work Lever / Joystick)739
- Safety Precautions739
- Structure Diagram740
- Parts List741
- Hydraulic Pressure Circuit Diagram742
- Performance Specification742
- Disassembly and Assembly Tool743
- Disassembly Method743
- Assembly Method746
Table of Contents753
- Applicable Models755
- Dozer Valve755
- Safety Precautions755
- Structure Diagram756
- Hydraulic Pressure Circuit Diagram757
- Performance Specification757
- Parts List758
- Disassembly759
- Disassembly and Assembly Tool759
- Assembly Method762
Table of Contents769
- Applicable Models771
- Safety Precautions771
- Travel Contorl Valve771
- General Description772
- Parts List772
- Hydraulic Pressure Circuit Diagram773
- Performance Specification773
- Maintenance774
- Required Tool and Tightening Torque774
- Maintenance Standard775
- Disassembly776
- Assembly781
- General Caution787
- Troubleshooting787
- Troubleshooting and Resolution787
Table of Contents791
- Applicable Models793
- Pedal Valve793
- Safety Precautions793
- General Description794
- Parts List794
- Specifications795
- Tools and Materials795
- Disassembly796
- Assembly798
Table of Contents815
- Applicable Models817
- Electrical System817
- Safety Precautions817
- Overview819
- Electrical Supply System820
- Engine Starting822
- Start Operation822
- After Start824
- Engine Preheating System825
- Engine Stop827
- Charging System828
- Instrument Panel829
- Instrument System829
- Function Check830
- Gauge831
- Operation831
- Warning Lights832
- Circuit Diagram of Instrument Panel834
- Control Unit Circuit835
- Engine Control System836
- Performance Specification836
- Engine Control Dial837
- Engine Control Circuit Diagram838
- Automatic Deceleration Control (Auto Idle Control)839
- Engine Overheat Protection System840
- Engine Control Unit841
- Control Failure Detection842
- Flashing Patterns of Engine Check Lamp845
- Fuel Injection Pump846
- EGR Valve847
- Refrigerant Circulation848
- Air-Conditioning System Circuit Diagram850
- Air Flow Control851
- Air Flow Control Motor852
- Blower Motor852
- Coolant Flow Control Valve853
- Temperature Level Control and Display854
- Weight of R134A Gas Used in Machines855
- Refrigerant Safe Handling Procedures856
- Refrigerant System Repairs856
- Repair and Replacement Procedure857
- Refrigerant Recovery859
- Vacuuming Refrigerant System859
- Leakage Check861
- Refrigerant Charging861
- Inspecting System for Leakage863
- Refrigerant Pressure Check864
- Troubleshooting864
- Applicable Models881
- Boom and Arm881
- Safety Precautions881
- Front Attachment Pin Specifications882
- Arm Removal Procedure884
- Front Attachment - Removal and Installation884
- Boom Removal Procedure886
- Arm Installation Procedure887
- Boom Installation Procedure887
- Installation887
- Start-Up Procedures887
- Applicable Models893
- Safety Precautions893
- Bucket Tooth Replacement894
- Bucket O-Ring Replacement896
- Bucket Attachment, Removal and Reversal897
- Detaching the Bucket897
- Attaching the Bucket898
- Reversing the Bucket898

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