Daewoo doosan dx85 r 3 excavator service repair manual (serial number 1001 and up)

Original InstructionsCopyright DOOSAN 2013
Serial Number 1001 and Up
Shop Manual
DX85R-3 Excavator
950106-01030E
April 2013
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

Table of Contents
Page I
1Table of Contents
Safety
Track Excavator Maintenance Safety................................................... SP003007
Specifications
Specification for DX85R-3 .................................................................... SP003008
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Upper Structure
Cabin .................................................................................................... SP003009
Swing Bearing....................................................................................... SP003010
Lower Structure and Chassis
Track Assembly .................................................................................... SP003011
Engine and Drivetrain
Engine................................................................................................... SP003012
Drive Coupling (Main Pump)................................................................. SP001635
Hydraulics
Accumulator.......................................................................................... SP002455
Center Joint (Swivel)............................................................................. SP001628
Cylinders............................................................................................... SP003027
Swing Device........................................................................................ SP003013
Travel Device........................................................................................ SP001638
Main Pump............................................................................................ SP001648
Main Control Valve ............................................................................... SP001691

Table of Contents
Page II
Remote Control Valve (Work Lever/Joystick)....................................... SP003015
Travel Control Valve ............................................................................. SP003016
Dozer Valve .......................................................................................... SP003017
Pilot Supply Valve................................................................................. SP003018
EPPR Valve.......................................................................................... SP003019
2nd Auxiliary Valve (Option) ................................................................. SP003020
Quick Coupler Valve (Option)............................................................... SP003021
Forced Regeneration Valve.................................................................. SP003022
Hydraulic Schematic............................................................................. SP003023
Electrical System
Electrical System .................................................................................. SP003024
Electrical Schematic ............................................................................. SP003025
Attachments
Boom and Arm...................................................................................... SP003026
Bucket................................................................................................... SP001643

SP003007
Page 1
Track Excavator Maintenance Safety
SP003007
TRACK EXCAVATOR MAINTENANCE SAFETY
SP003007
Track Excavator
Maintenance
Safety
Edition 1

SP003007
Page 5
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
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.
MODEL SERIAL NUMBER RANGE
DX85R-3 1001 and Up

SP003007Track Excavator Maintenance Safety
Page 6
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.
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.
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.
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.

SP003007
Page 7
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of 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.
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.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.

Page 8
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.

SP003007
Page 9
Proper Work Tools and Attachments
Only use work tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When installing and
using optional attachments, read instruction manual for
attachment, and general information related to attachments in
this manual. Because DOOSAN cannot anticipate, identify or
test all attachments that owners may want to install on their
machines, contact DOOSAN for written authorization and
approval of attachments, and their compatibility with optional
kits.
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or combination of work
equipment, there is a potential that work equipment could
interfere with the cabin or other parts of machine. Before using
unfamiliar work equipment, check if there is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
Never use attachment as a work platform or manlift.
Contact your DOOSAN distributor about auxiliary hydraulic kits
for attachments installation. If you are in doubt about
compatibility of a particular attachment with a machine, consult
your DOOSAN distributor.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure
to do so can result in death or serious injury.
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
FG018457
Figure 1

Page 10
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose to whip or oil
to spray. Fluid penetration can result in death or serious injury. If
fluid enters skin or eyes, get immediate medical attention from a
physician familiar with this injury.
Obey all local laws and regulations for disposal of liquids.
To prevent hot coolant from spraying out, stop engine and wait
for coolant to cool. Using gloves, slowly loosen cap to relieve
pressure.
Flying or Falling Objects
On work sites where there is a potential hazard that flying or
falling objects can hit operator's cabin, select and use a guard to
match operating conditions for additional operator protection.
Working in mines, tunnels, deep pits, and loose or wet surfaces,
could produce hazard of falling rocks or flying objects. Additional
protection for operator's cabin could be required such as an
Operator Protection Guard (OPG) or window guards. Contact
your DOOSAN distributor for information on available protective
guards.
To prevent personnel from being struck by flying objects, keep
personnel out of work area.
HAOA110L
Figure 2
HAOA100L
Figure 3

SP003010
Page 1
Swing Bearing
SP003010
SWING BEARING SP003010
Swing Bearing
Edition 1

SP003010
Page 5
Swing Bearing
SAFETY INSTRUCTIONS
APPLICABLE MODELS
WARNING
or serious injury.
DX62R-3 1001 and Up
DX63-3 1001 and Up
DX85R-3 1001 and Up

SP003010Swing Bearing
Page 6
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.
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
1
2
Figure 1

SP003010
Page 7
Swing Bearing
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.
Disassembly
1. Remove tip of tapered pin (1, Figure 3) using grinder and
tap lightly to remove debris.
2. Remove plug (1, Figure 4) using a M10 x 1.25 bolt (2).
Figure 2
Reference
Number
Description
1 Ball
2 Seal A
3 Retainer
4 Outer Ring
5 Inner Ring
6 Tapered Pin
7 Plug
Figure 3
Figure 4

SP003010Swing Bearing
Page 8
3. Lift outer ring and check that inner ring can move freely.
See Figure 5, if not, replace seal (3, Figure 4).
4. Turn inner ring and use magnet bar (1, Figure 6) to remove
steel balls (2).
5. Turn inner ring and use wire (1, Figure 7) to remove
retainers (2).
Figure 5
Figure 6
Figure 7

SP003010
Page 9
Swing Bearing
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.
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.
3. Top 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 8
Figure 9
Figure 10
Figure 11

SP003011
Page 5
Track Assembly
SAFETY INSTRUCTIONS
APPLICABLE MODELS
WARNING
or serious injury.
DX85R-3 1001 and Up

SP003011Track Assembly
Page 6
TRACKS
Specification and Construction
Steel Track
Track Frame
Figure 1
FG013334
Track Frame
Lower Roller Track Adjuster
Figure 2

SP003011
Page 7
Track Assembly
TRACK TENSION
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.
Inspection
1. Turn upper body so it is at a 90° angle to tracks.
NOTE: On rubber tracks, move machine body so seam
of tracks pad is on axle centerline, then turn
body.
2. Use the boom and arm to raise the machine.
3. Place blocking underneath the machine.
4. Raise the boom until the weight of the machine is resting
on the blocks.
5. Stop the engine.
Turn the track backward 1 - 2 turns.
WARNING
Measurement of track tension requires two people. Always
follow these instructions:
• One person must be in the operator's seat operating
the controls while the other person makes dimensional
checks.
• Block frame to make sure the machine won't move or
shift position during service.
• Warm up the engine to prevent stalls.
• Park the 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 grease pressure too fast. The track tension
grease valve should never be backed off more than one (1)
complete turn from the fully tightened down position. Bleed
off grease pressure slowly. Always keep your body away
from the valve. Always wear eye and face protection when
adjusting track tension.
90 ~ 100
FG028476
Figure 2

Page 8
6. Measure clearance between track roller and track contact
surfaces. Clearance must be approximately 10 - 15 mm
(0.39 - 0.59 in)
NOTE: This measurement can be thrown off if there is
too much mud or dirt or other material in track
assembly. Clean off tracks before checking
clearance.
NOTE: For machines with rubber tracks (optional),
checking and adjustment steps and clearance
are the same.
10 ~ 15 mm
FG007705
Figure 3
Figure 4
Figure 5
WARNING
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 grease pressure slowly.
Always keep your body away from the valve. Always
wear eye and face protection when adjusting track
tension.

SP003011
Page 9
Track Assembly
How to Increase Tension
1. Apply grease through grease fitting.
2. Move track forward and backward to distribute grease and
readjust tension if necessary.
3. If tension cannot be increased, replace pin and bushing,
or, on rubber tracks, replace cylinder seal or tracks.
To Reduce Tension
1. Loosening track tension grease valve causes grease to
drain out and track tension to decrease. Loosen valve
slowly to a maximum of 1 turns.
2. When track tension is correct, tighten track tension grease
valve to 59 - 88 Nm/6 - 9 kg•m (43 - 65 ft lb)
3. Recheck tension by moving track forward and backward.
4. Recheck tension and adjust as necessary.
FG028453
Figure 6
Figure 7

Page 10
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
The tables that follow provide factory specified dimensional
limits (as new condition, recommended service and replacement
limit) for lower travel frame components.
Recommended 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.
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.

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SP003011
Page 11
Track Assembly
Rubber Track
The amount of friction of rubber track sets limit of use. However, it is
subject to change depending upon work condition and environment.
0
5
10
15
20
500 1000 1500 2000 2500 3000
FG008467
Amount of friction
Operating hours(H)
Limit of use
Figure 8
Figure 9
Figure 10
Item Dimension
Distance Between Centers of Tracks
5,994 ±10 mm
(235.98 ±0.39 in)
Scale Cord Rigid
1,000.0 kg
(2,200 lb)
Scale Cord Number of Coils 64 ±4
Range of Temperature for Use
-25°C - 55°C
(-13° - 131°F)
Width x Pitch
450 x 81 mm
(17.72 x 3.19 in)

Page 12
Steel Track
5
4
2
1
3
FG010287
Figure 11
No. Item Standard Limits Remarks
1 Link Pitch 154 mm (6.067 in) 156 mm (6.142 in)
2 Link Height 74 mm (2.913 in) 70 mm (2.758 in) Build up or replace.
3 Track Height 20 mm (0.787 in) 15 mm (0.59 in) Build up or replace.
4 Pin Clearance 0.29 mm (0.01 in) 2.0 mm (0.08 in) Replace.
5 Bushing Thickness 41.26 mm (1.624 in) 39.5 mm (1.555 in) Replace.

SP003011
Page 13
Track Assembly
Track Frame Spring
23
1 4
FG013337
Figure 12
No. Item Criteria Remarks
1 Deformed frame
Limit
Bent
Bending 5 (Overall length of track frame)
Distorted
10 (Distortion between left and right
track frames)
Widened idler
5.0 mm
(0.20 in)
2
Gap between upper
and lower sides of
idler guide.
Standards Limits
Build up or replace
Track frame
74 mm
(2.91 in)
79 mm
(3.11 in)
Idler frame
72 mm
(2.83 in)
67 mm
(2.64 in)
3
Gap between left and
right of idler guide.
Idler support
162 mm
(6.37 in)
167 mm
(6.57 in)
Build up or replace
Track frame
170 ±0.5 mm
(6.69 ±0.02 in)
165.0 mm
(6.5 in)
4
Track spring
(Standards)
Free length Installed load Installed length
Replace447 mm
(17.60 in)
4,600 kg
(10,141 lb)
361 mm
(14.21 in)

Daewoo doosan dx85 r 3 excavator service repair manual (serial number 1001 and up)

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Daewoo doosan dx85 r 3 excavator service repair manual (serial number 1001 and up)