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Daewoo doosan dx63 3 excavator service repair manual (serial number 1001 and up)
1. Original InstructionsCopyright DOOSAN 2013
Serial Number 1001 and Up
Shop Manual
DX62R-3/DX63-3 Excavator
950106-01085E
June 2013
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
2. Table of Contents
Page 1
1Table 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
Accumulator.......................................................................................... SP002455
Center Joint (Swivel)............................................................................. SP001628
Cylinders............................................................................................... SP003044
Swing Device........................................................................................ SP001630
Travel Device........................................................................................ SP001686
Main Pump............................................................................................ SP003045
3. Table of Contents
Page 2
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
5. SP003041
Page 5
Track Excavator Maintenance Safety
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
DX62R-3 1001 and Up
DX63-3 1001 and Up
6. SP003041Track 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.
7. SP003041
Page 7
Track Excavator Maintenance Safety
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.
8. SP003041Track Excavator Maintenance Safety
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.
10. SP003010
Page 5
Swing Bearing
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
DX62R-3 1001 and Up
DX63-3 1001 and Up
DX85R-3 1001 and Up
11. 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
12. 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
13. 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
14. 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. 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 8
Figure 9
Figure 10
Figure 11
16. SP003043
Page 5
Track Assembly
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
DX62R-3 1001 and Up
DX63-3 1001 and Up
18. SP003043
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.
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.
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.
EX1300539
90 - 110
Figure 3
19. SP003043Track Assembly
Page 8
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.
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.
4. The increased clearance recommended for muddy, sandy
or snowy ground conditions is between 130 - 135 mm
(5.12 - 5.31 in).
A
EX1300538
Figure 4
A
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.
20. SP003043
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.
FG013228
Figure 6
Figure 7
21. SP003043Track Assembly
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.
22. SP003043
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
5,510 ±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
-25°C - 55°C
(-13° - 131°F)
Width x Pitch
400 x 72.5 mm
(15.74 x 2.85 in)
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24. SP003043Track Assembly
Page 12
Steel Track
5
4
2
1
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.
25. SP003043
Page 13
Track Assembly
Track Frame Spring
23
1
FG013227
4
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
69.0 mm
(2.71 in)
74.0 mm
(2.91 in)
Idler Frame
67.0 mm
(2.64 in)
62.0 mm
(2.44 in)
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
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
Replace303.6 mm
(11.95 in)
3,700 kg
(8,157 lb)
265 mm
(10.4 in)
26. SP003043Track Assembly
Page 14
Idler
Steel Tracks
3
4
6
7
2
1
5
FG010668
Figure 13
No. Item Standard Limits Remarks
1 Diameter of Flange
365.0 mm
(14.37 in)
- -
2 Diameter of Link
328 mm
(12.91 in)
316 mm
(12.44 in)
Repair
3 Front Width
98 mm
(3.86 in)
- -
4 Flange Width
46.6 mm
(1.83 in)
5 Thread Width
25.6 mm
(1.01 in)
31.1 mm
(1.22 in)
Repair
6 Shaft-Bushing Clearance
Standard
Dimension
Tolerance Standard
Clearance
Allowable wear limit
Shaft Hole
34 mm
(1.34 in)
33.95 34.32
Max:
0.39
Undefinable
33.925 34.21
Min:
0.26
7 Body-Bushing Press Fit
Standard
Dimension
Tolerance Standard
Press Fit
Allowable wear limit
Bushing Hole
38 mm
(1.49 in)
38.103 38.05
Max:
-0.083
Nonoccurrence
38.078 38.02
Min:
0.28
