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 950106-01085E
world. June 2013

Copyright DOOSAN 2013 Original Instructions

 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

Table of Contents
Page 1
 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
 SP003041
TRACK EXCAVATOR MAINTENANCE SAFETY
SP003041

Track Excavator
Maintenance
Safety
Edition 1

Track Excavator Maintenance Safety SP003041

Page 1
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

Track Excavator Maintenance Safety SP003041

Page 5
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 SP003041

Page 6
 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.

Track Excavator Maintenance Safety SP003041

Page 7
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 SP003041

Page 8
 SP003010
SWING BEARING SP003010

Swing Bearing

Edition 1

Swing Bearing SP003010

Page 1
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

Swing Bearing SP003010

Page 5
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 1
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).
2
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 EX1300031
bucket tip just off the ground, push against the bucket sideways Figure 1
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.

Swing Bearing SP003010

Page 6
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
Description
Number
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

Swing Bearing SP003010

Page 7
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 SP003010

Page 8
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

Swing Bearing SP003010

Page 9
 SP003043
TRACK ASSEMBLY SP003043

Track
Assembly

Edition 1

Track Assembly SP003043

Page 1
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

Track Assembly SP003043

Page 5
TRACKS

Specification and Construction

Steel Tracks

Figure 1

Track Frame

Track Frame

Lower Roller Track Adjuster

FG013225
Figure 2

Track Assembly SP003043

Page 6
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

Track Assembly SP003043

Page 7
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
A
checking clearance.

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 A
track assembly. Clean off the tracks before
checking clearance.
4. The increased clearance recommended for muddy, sandy
FG000162
or snowy ground conditions is between 130 - 135 mm
Figure 5
(5.12 - 5.31 in).

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 SP003043

Page 8
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.

FG013228
Figure 6

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.

Figure 7

Track Assembly SP003043

Page 9
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.
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.

Track Assembly SP003043

Page 10
Rubber Track

Amount of friction Limit of use

20

15

10

0 500 1000 1500 2000 2500 3000

Operating hours(H)
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 Dimension
5,510 ±15 mm
Distance Between Centers of Tracks
(216.93 ±0.59 in)
1,000.0 kg
Scale Cord Rigid
(2,200 lb)
Scale Cord Number of Coils 44 ±4
-25°C - 55°C
Range of Temperature for Use
(-13° - 131°F)
400 x 72.5 mm
Width x Pitch
(15.74 x 2.85 in)
Figure 10

Track Assembly SP003043

Page 11
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Steel Track

2
4

3
FG010287
Figure 11

No. Item Standard Limits Remarks

135 mm 137 mm
1 Link Pitch
(5.32 in) (5.4 in)
70.0 mm 67.5 mm
2 Link Height Build up or replace.
(2.75 in) (2.66 in)
14 ±1 mm 9.0 mm
3 Track Height Build up or replace.
(0.55 ±0.04 in) (0.35 in)
0.15 mm 2.0 mm
4 Pin Clearance Replace.
(0.01 in) (0.08 in)
39 mm 37.6 mm
5 Bushing Thickness Replace.
(1.53 in) (1.48 in)

Track Assembly SP003043

Page 12
Track Frame Spring

3
1
4

2
FG013227
Figure 12

No. Item Criteria Remarks

Limit
Bending 5 (Overall length of track frame)
1 Deformed Frame 10 (Distortion between left and right Bent
Distorted
track frames)
5.0 mm
Widened Idler
(0.20 in)
Standards Limits
Gap between upper 69.0 mm 74.0 mm
Track Frame
2 and lower sides of (2.71 in) (2.91 in) Build up or replace
idler guide. 67.0 mm 62.0 mm
Idler Frame
(2.64 in) (2.44 in)
166.0 mm 171.0 mm
Idler Support
Gap between left and (6.54 in) (6.73 in)
3 Build up or replace
right of idler guide. 170 ±0.5 mm 165.0 mm
Track Frame
(6.69 ±0.02 in) (6.5 in)
Free Length Installed load Installed length
Track Spring
4 303.6 mm 3,700 kg 265 mm Replace
(Standards)
(11.95 in) (8,157 lb) (10.4 in)

Track Assembly SP003043

Page 13
Idler

Steel Tracks

6
7
2
1
4 5
3
FG010668
Figure 13

No. Item Standard Limits Remarks

365.0 mm
1 Diameter of Flange - -
(14.37 in)
328 mm 316 mm
2 Diameter of Link Repair
(12.91 in) (12.44 in)
98 mm
3 Front Width - -
(3.86 in)
46.6 mm
4 Flange Width
(1.83 in)
25.6 mm 31.1 mm
5 Thread Width Repair
(1.01 in) (1.22 in)
Standard Tolerance Standard
Allowable wear limit
Dimension Shaft Hole Clearance

6 Shaft-Bushing Clearance Max:

33.95 34.32
34 mm 0.39
Undefinable
(1.34 in) Min:
33.925 34.21
0.26
Standard Tolerance Standard
Allowable wear limit
Dimension Bushing Hole Press Fit

7 Body-Bushing Press Fit Max:

38.103 38.05
38 mm -0.083
Nonoccurrence
(1.49 in) Min:
38.078 38.02
0.28

Track Assembly SP003043

Page 14