Daewoo Doosan DX62R-3, DX63-3 Excavator Service Repair Manual Instant Download (Serial Number 1001 and Up)

1
Shop Manual DX62R-3/DX63-3 Excavator
Serial Number 1001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-01085E June 2013
Original Instructions
Copyright DOOSAN 2013
2
Table of Contents
Safety Track Excavator Maintenance Safety
..................................................
. SP003041 Specifications Specification for
DX62R-3/DX63-3 ...................................
.................... SP003042 General
Maintenance General Maintenance Instructions
..................................................
...... SP002454 Standard Torques
..................................................
............................... SP002404 Upper
Structure Cabin ..................................
..................................................
................ SP003058 Swing
Bearing...........................................
............................................
SP003010 Lower Structure and Chassis Track
Assembly .........................................
...........................................
SP003043 Engine and Drivetrain Engine
(Europe)..........................................
..........................................
SP003057 Engine...................................
..................................................
.............. SP003012 Drive Coupling (Main
Pump).............................................
.................... SP001627 Hydraulics Accumula
tor...............................................
...........................................
SP002455 Center Joint (Swivel)....................
..................................................
....... SP001628 Cylinders........................
..................................................
..................... SP003044 Swing Device
..................................................
......................................
SP001630 Travel Device............................
..................................................
.......... SP001686 Main Pump.....................
..................................................
..................... SP003045
Table of Contents Page 1
3
Main Control Valve ...............................
................................................
SP003046 Remote Control Valve (Work
Lever/Joystick) ..................................
..... SP003015 Travel Control Valve
..................................................
........................... SP003016 Dozer Valve
..................................................
........................................
SP003056 Pilot Supply Valve.......................
..................................................
........ SP003047 EPPR Valve .....................
..................................................
................... SP003019 2nd Auxiliary Valve
(Option) .........................................
........................ SP003048 Quick Coupler
Valve (Option) ...................................
............................ SP003021 Forced
Regeneration Valve ...............................
...................................
SP003022 Hydraulic Schematic......................
..................................................
..... SP003049 Electrical System Electrical
System (Europe) ..................................
.................................
SP003050 Electrical System .......................
..................................................
......... SP003024 Electrical Schematic
..................................................
........................... SP003025 Attachments
Boom and Arm......................................
................................................
SP003055 Bucket...................................
..................................................
.............. SP001643
Table of Contents Page 2
4
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Track Excavator Maintenance
Safety
SP003041
Edition 1
Track Excavator Maintenance Safety
SP003041 Page 1
6
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation
Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments
repairs or service. Untrained operators and
failure to follow instructions can cause death or
serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX62R-3 1001 and Up
DX63-3 1001 and Up
SP003041 Page 5
Track Excavator Maintenance Safety
7
SAFETY MESSAGES Safety messages and safety decals
included in this manual and on the machine
provide instructions how to operate, service and
maintain the machine. Safety messages and safety
decals indicate potential hazards and describe
safety precautions required to avoid hazards.
Operator and maintenance personnel should read
and understand these safety messages and decals
before beginning operation or maintenance.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and
Safety Instructions. This is a Safety Alert
Symbol. Wherever it appears in this manual or on
safety decals on the machine, you must be alert
to the potential for personal injury or
accidents. Always observe safety precautions
and follow recommended procedures. Signal
Words The signal words "DANGER", "WARNING",
"CAUTION" are used throughout safety messages and
safety decals in this manual or on the machine.
They indicate an existence of, and the relative
seriousness of, a hazard. All three indicate that
a safety risk is involved. Observe the
precautions indicated whenever a Safety Alert
Symbol is present, no matter which signal word
appears next to it.
DANGER
DANGER - This signal word is used on safety
messages and safety labels and indicates an
imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety
messages and safety labels and indicates a
potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Track Excavator Maintenance Safety Page 6
SP003041
8
CAUTION
CAUTION - This signal word is used on safety
messages and safety labels and indicates a
potentially hazardous situation which, if not
avoided, could result in minor or moderate
injury. Other Signal Words In addition to
safety signal words, the following signal words
are used to indicate proper and effective use of
machine.
IMPORTANT
This signal word identifies procedures which must
be followed to avoid damage to machine. The word
"NOTE" identifies information for effective use.
SAFETY DECALS Location of safety labels (decals)
can vary from unit to unit. Refer to appropriate
Operation Maintenance Manual, and parts manual
for your unit. Always replace damaged or faded
decals.
SP003041 Page 7
Track Excavator Maintenance Safety
9
GENERAL

• Safe Operation is Operator's Responsibility
• Only trained and authorized personnel should
  operate and maintain the machine.
• Follow all safety rules, regulations and
  instructions when operating or performing
  maintenance on machine.
• Do not operate machine if you are under the
  influence of drugs or alcohol. An operator who
  is taking prescription drugs must get medical
  advice to determine if he or she can safely
  operate a machine.
• When working with other personnel on a work site,
  be sure that all personnel know nature of work
  and understand all hand signals that are to be
  used.
• Be sure that all guards and shields are installed
  in their proper location. Have guards and
  shields repaired or replaced immediately if
  damaged.
• Be sure that you understand the use and
  maintenance of all safety features such as
  safety lock lever and seat belt. Use them
  properly.
• Never remove, modify or disable any safety
  features. Always keep them in good operating
  condition.
• Always check for and know the location of
  underground and overhead utility lines before
  excavating.
• Failure to use and maintain safety features
  according to instructions in this manual, Safety
  Manual and Shop Manual can result in death or
  serious injury.
• Know Your Machine
• Know how to operate your machine. Know the
  purpose of all controls, gauges, signals,
  indicators and monitor displays. Know the rated
  load capacity, speed range, braking and steering
  characteristics, turning radius and operating
  clearances. Keep in mind that rain, snow, ice,
  loose gravel, soft ground, slopes etc., can
  change operating capabilities of your machine.

Track Excavator Maintenance Safety Page 8
SP003041
10
Swing Bearing
SP003010
Edition 1
Swing Bearing
SP003010 Page 1
11
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation
Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments
repairs or service. Untrained operators and
failure to follow instructions can cause death or
serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX62R-3 1001 and Up
DX63-3 1001 and Up
DX85R-3 1001 and Up
SP003010 Page 5
Swing Bearing
12
SWING BEARING MAINTENANCE
Operating Recommendation The service life of the
swing bearing may be extended if a conscious,
daily effort is made to equalize usage over both
ends of the excavator. If the excavator is used
in the same operating configuration day in and
day out (for example, with the travel motors
always under the counterweight, or with the
attachment over one side of the machine more than
the other), the bearing's service life could be
reduced. Repositioning the excavator during the
work shift to work the opposite end of the
bearing, will provide a more even and gradual
rate of wear and extended service life.
Measuring Swing Bearing Axial Play Periodic,
regular checks of bearing displacement must be
made at least twice a year. Use a dial indicator.
Push the attachment against the ground to lift
the excavator off the ground and take
measurements at 4 points, 90 apart, around the
circumference of the bearing (Figure 1). Record
and keep all measurements. Play in the bearing
should increase minimally from one inspection to
the next. Eventually, however, as the bearing
begins to approach the limit of its service
life, clearance increases become much more
pronounced and the actual measured play in the
bearing could exceed twice the value that was
measured when the machine was new.
1
2
Measuring Bearing Lateral Play When vertical
checks are made, the side to side play in the
bearing can be checked by fully retracting the
arm and bucket cylinders and extending the tip of
the bucket as far forward as it will go. With the
excavator parked on a flat, level surface and the
bucket tip just off the ground, push against the
bucket sideways to take up all the lateral
clearance in the bearing. (Less than 100 lb of
force must be required to move the bucket over
all the way.) Check lateral play in both
directions and record the values. When the
bearing is beginning to approach the end of its
service life, measured lateral clearance should
start to show increase in value.
EX1300031
Figure 1
Swing Bearing Page 6
SP003010
13
Swing Bearing Basic Operation The swing bearing,
which connects the upper structure with the lower
structure, consists of an inner ring, outer ring
and ball bearings. During swing movement, power
from the swing motor is transferred to the pinion
by planetary gears connected to gears on the
inner ring, which is fixed in the undercarriage.
Ball bearings turn the outer ring.
Reference Number Description
1 Ball
2 Seal A
3 Retainer
4 Outer Ring
5 Inner Ring
6 Tapered Pin
7 Plug
Figure 2
Disassembly 1. Remove tip of tapered pin (1,
Figure 3) using grinder and tap lightly to remove
debris.
Figure 3 2. Remove plug (1, Figure 4) using a
M10 x 1.25 bolt (2).
Figure 4
SP003010 Page 7
Swing Bearing
14
3. Lift outer ring and check that inner ring can
move freely. See Figure 5, if not, replace seal
(3, Figure 4).
Figure 5 4. Turn inner ring and use magnet bar
(1, Figure 6) to remove steel balls (2).
Figure 6 5. Turn inner ring and use wire (1,
Figure 7) to remove retainers (2).
Figure 7
Swing Bearing Page 8
SP003010
15
Assembly 1. Clean (degrease) the seal groove for
the outer and inner seals (7). Apply instant glue
to seal (7). Install both seals respectively into
position.
Figure 8 2. Hoist the outer race by crane
horizontally and match it with the inner race
coaxially. Rotating the outer race, insert balls
(5), support (6) into the plug (4) hole one by
one with a round bar.
Figure 9
Figure 10 3. Install plug (4) into outer race
(1) and then, drive pin (3) into the
pinhole. Caulk the head of pin (3) with a punch.
Fill grease through the grease fitting.
Figure 11
SP003010 Page 9
Swing Bearing
16
Track Assembly
SP003043
Edition 1
Track Assembly
SP003043 Page 1
17
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation
Maintenance Manual and signs (decals) on machine.
Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing.
Check for correct function after adjustments
repairs or service. Untrained operators and
failure to follow instructions can cause death or
serious injury.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DX62R-3 1001 and Up
DX63-3 1001 and Up
SP003043 Page 5
Track Assembly
18
TRACKS Specification and Construction
Steel Tracks
Figure 1 Track Frame
Track Frame
Lower Roller
Track Adjuster
FG013225
Figure 2
Track Assembly Page 6
SP003043
19
TRACK TENSION WARNING

• AVOID DEATH OR SERIOUS INJURY
• Measurement of track tension requires two people.
  Always follow these instructions
• One person must be in the operator's seat running
  the controls to keep one side frame in the air,
  while the other person makes dimensional checks.
• Take all necessary precautions to make sure the
  machine does not move or shift position during
  service.
• Warm up the engine to prevent stalls.
• Position excavator in an area that provides
  level, uniform ground support and/or use support
  blocks when necessary.
• The track adjusting mechanism is under very
  high-pressure. NEVER release pressure too
  suddenly. The track tension grease valve should
  never be backed off more than one (1) complete
  turn from the fully tightened down position.
  Bleed off pressure slowly and keep your body away
  from the valve always.
• Track shoe link pins and bushings wear with
  normal usage, reducing track tension. Periodic
  adjustment is necessary to compensate for wear
  and it may also be required by working
  conditions.
• 1. Track tension is checked by jacking up one
  side of the excavator. See Figure 3. Place
  blocking under frame while taking measurement.
• Turn the track backward 1 - 2 turns.

90
- 110
EX1300539
Figure 3
SP003043 Page 7
Track Assembly
20
2. For machines with rubber tracks, measuring
the distance (A, Figure 4) between the bottom of
the side frame and the top of the lowest crawler
shoe. Recommended tension for operation over most
types of terrain is 66 - 71 mm (2.60 - 2.80 in).
NOTE
This measurement can be inaccurate if there is
too much mud or dirt or other material in the
track assembly. Clean off the tracks before
checking clearance.
A
EX1300538
Figure 4 3. For machines with steel tracks,
measuring the distance (A, Figure 5) between the
bottom of the side frame and the top of the
lowest crawler shoe. Recommended tension for
operation over most types of terrain is 125 - 130
mm (4.92 - 5.12 in).
NOTE
This measurement can be inaccurate if there is
too much mud or dirt or other material in the
track assembly. Clean off the tracks before
checking clearance.
A
4. The increased clearance recommended for
muddy, sandy or snowy ground conditions is
between 130 - 135 mm (5.12 - 5.31 in).
FG000162
Figure 5
WARNING
AVOID DEATH OR SERIOUS INJURY The track
adjusting mechanism is under very
high-pressure. NEVER release pressure too
suddenly. The track tension grease valve should
never be backed off more than one (1) complete
turn from the fully tightened down position.
Bleed off pressure slowly and keep your body away
from the valve always. If there is problem in the
valve thread, the valve might be ejected at
high-speed and cause death or serious injury.
Track Assembly Page 8
SP003043
21

• How to Increase Tension
• Apply grease through grease fitting.
• Move track forward and backward to distribute
  grease and readjust tension if necessary.
• If tension cannot be increased, replace pin and
  bushing, or, on rubber tracks, replace cylinder
  seal or tracks.

FG013228
Figure 6

• To Reduce Tension
• Loosening track tension grease valve causes
  grease to drain out and track tension to
  decrease. Loosen valve slowly to a maximum of 1
  turns.
• When track tension is correct, tighten track
  tension grease valve to 59 - 88 Nm/6 - 9 kgm
  (43 - 65 ft lb)
• Recheck tension by moving track forward and
  backward.
• Recheck tension and adjust as necessary.
• Figure 7

SP003043 Page 9
Track Assembly
22
CLEANING AND INSPECTION (WEAR LIMITS AND
TOLERANCES) CAUTION
AVOID INJURY Refer to "Welding Precautions and
Guidelines" information in "General Maintenance
Procedures" section for general recommendations
and specific safety precautions, before starting
any lower travel frame component rebuilding
procedure. The tables that follow provide
factory specified dimensional limits (as new
condition, recommended service and replacement
limit) for lower travel frame components. Recommen
ded maintenance to renew most listed components
requires welding on additional material and
grinding off excess. Some components must be
replaced before the service limit is exceeded. No
maintenance or renewal is possible. Compare the
values in the tables with dimensions and profiles
shown in the following figures.
Track Assembly Page 10
SP003043
23
Rubber Track
Amount of friction
Limit of use
20 15 10 5
500
1500
2000
2500 3000 Operating hours(H)
0
1000
FG008467
Figure 8 The amount of friction of rubber track
sets limit of use. However, it is subject to
change depending upon work condition and
environment.
Figure 9
Item Item Dimension
Distance Between Centers of Tracks Distance Between Centers of Tracks 5,510 15 mm (216.93 0.59 in)
Scale Cord Rigid 1,000.0 kg (2,200 lb)
Scale Cord Number of Coils 44 4
Range of Temperature for Use Range of Temperature for Use -25C - 55C (-13 - 131F)
Width x Pitch Width x Pitch 400 x 72.5 mm (15.74 x 2.85 in)
Figure 10
SP003043 Page 11
Track Assembly
24
Steel Track
1
5
2
4
3
FG010287
Figure 11
No. Item Standard Limits Remarks
1 Link Pitch 135 mm (5.32 in) 137 mm (5.4 in)
2 Link Height 70.0 mm (2.75 in) 67.5 mm (2.66 in) Build up or replace.
3 Track Height 14 1 mm (0.55 0.04 in) 9.0 mm (0.35 in) Build up or replace.
4 Pin Clearance 0.15 mm (0.01 in) 2.0 mm (0.08 in) Replace.
5 Bushing Thickness 39 mm (1.53 in) 37.6 mm (1.48 in) Replace.
Track Assembly Page 12
SP003043
25
Track Frame Spring
3
1
4
2
FG013227
Figure 12
No. Item Criteria Criteria Criteria Remarks
1 Deformed Frame Limit Limit Bent
1 Deformed Frame Bending 5 (Overall length of track frame) 5 (Overall length of track frame) Bent
1 Deformed Frame Distorted 10 (Distortion between left and right track frames) 10 (Distortion between left and right track frames) Bent
1 Deformed Frame Widened Idler 5.0 mm (0.20 in) 5.0 mm (0.20 in) Bent
2 Gap between upper and lower sides of idler guide. Standards Limits Build up or replace
2 Gap between upper and lower sides of idler guide. Track Frame 69.0 mm (2.71 in) 74.0 mm (2.91 in) Build up or replace
2 Gap between upper and lower sides of idler guide. Idler Frame 67.0 mm (2.64 in) 62.0 mm (2.44 in) Build up or replace
3 Gap between left and right of idler guide. Idler Support 166.0 mm (6.54 in) 171.0 mm (6.73 in) Build up or replace
3 Gap between left and right of idler guide. Track Frame 170 0.5 mm (6.69 0.02 in) 165.0 mm (6.5 in) Build up or replace
4 Track Spring (Standards) Free Length Installed load Installed length Replace
4 Track Spring (Standards) 303.6 mm (11.95 in) 3,700 kg (8,157 lb) 265 mm (10.4 in) Replace
SP003043 Page 13
Track Assembly
26
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Idler Steel Tracks
6 7 2 1
4 5 3
FG010668
Figure 13
No. Item Standard Standard Limits Limits Remarks
1 Diameter of Flange 365.0 mm (14.37 in) 365.0 mm (14.37 in) - - -
2 Diameter of Link 328 mm (12.91 in) 328 mm (12.91 in) 316 mm (12.44 in) 316 mm (12.44 in) Repair
3 Front Width 98 mm (3.86 in) 98 mm (3.86 in) - - -
4 Flange Width 46.6 mm (1.83 in) 46.6 mm (1.83 in)
5 Thread Width 25.6 mm (1.01 in) 25.6 mm (1.01 in) 31.1 mm (1.22 in) 31.1 mm (1.22 in) Repair
6 Shaft-Bushing Clearance Standard Dimension Tolerance Tolerance Standard Clearance Allowable wear limit
6 Shaft-Bushing Clearance Standard Dimension Shaft Hole Standard Clearance Allowable wear limit
6 Shaft-Bushing Clearance 34 mm (1.34 in) 33.95 34.32 Max 0.39 Undefinable
6 Shaft-Bushing Clearance 34 mm (1.34 in) 33.925 34.21 Min 0.26 Undefinable
7 Body-Bushing Press Fit Standard Dimension Tolerance Tolerance Standard Press Fit Allowable wear limit
7 Body-Bushing Press Fit Standard Dimension Bushing Hole Standard Press Fit Allowable wear limit
7 Body-Bushing Press Fit 38 mm (1.49 in) 38.103 38.05 Max -0.083 Nonoccurrence
7 Body-Bushing Press Fit 38 mm (1.49 in) 38.078 38.02 Min 0.28 Nonoccurrence
SP003043
Track Assembly Page 14
28
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