Doosan DX60R Shop Manual
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Doosan DX60R Shop Manual

Doosan DX60R Shop Manual

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Table of Contents

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DX60R
Shop Manual
K1042957E
Serial Number 50001 and Up
DOOSAN reserves the right to improve its products continuously, delivering the best possible product to
the marketplace. These improvements can be implemented at any time with no obligation to change
materials previously sold. It is recommended that consumers periodically contact their distributors for
most recent documentation on purchased equipment.
This documentation may include attachments and optional equipment not available in your machine's
package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
K1042957E Shop Manual
Copyright 2008 DOOSAN

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Summary of Contents for Doosan DX60R

  • Page 1 K1042957E Serial Number 50001 and Up DOOSAN reserves the right to improve its products continuously, delivering the best possible product to the marketplace. These improvements can be implemented at any time with no obligation to change materials previously sold. It is recommended that consumers periodically contact their distributors for most recent documentation on purchased equipment.
  • Page 3 Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine Pub. No. K1042957E...
  • Page 5 Table of Contents Safety Track Excavator Safety................SP001614 Specifications Specification for DX60R.................SP001615 General Maintenance General Maintenance Procedures............SP000016 Standard Torques..................SP000813 Upper Structure Cabin .....................SP001623 Swing Bearing ..................SP001624 Lower Structure and Chassis Track Assembly ..................SP001625 Engine and Drive Train Engine....................SP001693 Drive Coupling (Main Pump) ..............SP001627 Hydraulics Accumulator ..................SP000028...
  • Page 6 Remote Control Valve (Work Lever / Joystick) ........SP001640 Dozer Valve ...................SP001490 Travel Contorl Valve................SP001641 Pedal Valve....................SP001073 Hydraulic Schematic ................SP001692 Electrical System Electrical System ...................SP001687 Electrical Schematic (DX60R/DX80R) ...........SP001688 Attachments Boom and Arm..................SP001642 Bucket....................SP001643 Table of Contents Page II...
  • Page 7 Safety...
  • Page 9 SP001614 TRACK EXCAVATOR SAFETYSP001614 Track Excavator Safety Edition 1 Track Excavator Safety SP001614 Page 1...
  • Page 10 MEMO Track Excavator Safety SP001614 Page 2...

  • Page 11: Table Of Contents

    Table of Contents Track Excavator Safety Safety Precautions..........5 Applicable Models ..........5 To the Operator of a Excavator ......6 General Safety Essentials........10 Location of Safety Labels ........11 Summary of Safety Precautions for Lifting in Digging Mode............. 11 Unauthorized Modifications........
  • Page 12 MEMO Track Excavator Safety SP001614 Page 4...

  • Page 13: Track Excavator Safety

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Track Excavator Safety SP001614 Page 5...

  • Page 14: To The Operator Of A Excavator

    TO THE OPERATOR OF A EXCAVATOR DANGER Unsafe use of the excavator could lead to serious injury or death. Operating procedures, maintenance and equipment practices or traveling or shipping methods that do not follow the safety guidelines on the following pages could cause serious, potentially fatal injuries or extensive damage to the machine or nearby property.
  • Page 15 In no event should you or others engage in prohibited uses or actions as described in this manual. DOOSAN delivers machines that comply with all applicable regulations and standards of the country to which it has been sent. If this machine has been purchased in another...
  • Page 16 SAFETY ALERT SYMBOL Be Prepared - Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears in this manual or on safety signs on the machine you should be alert to the potential for personal injury or accidents. Always observe safety...
  • Page 17 Safety precautions are described in SAFETY from page -11 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or...

  • Page 18: General Safety Essentials

    The excavator has been primarily designed for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN for proper installation and application. Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading.

  • Page 19: Location Of Safety Labels

    LOCATION OF SAFETY LABELS Location of safety labels (decals) can vary from unit to unit. Refer to appropriate Operation and Maintenance Manual, and parts manual for your unit. Always replace damaged or faded decals. SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING IN DIGGING MODE DANGER Unsafe use of the excavator while making rated lifts could...
  • Page 20 If you need more information or have any questions or concerns about safe operating procedures or working the excavator correctly in a particular application or in the specific conditions your individual operating environment, please consult your local DOOSAN representative. Track Excavator Safety SP001614 Page 12...

  • Page 21: Unauthorized Modifications

    UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner will be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking...
  • Page 22 Inside Operator's Cabin When entering the operator's cabin, always remove all mud and oil from the soles of your shoes. If you operate the travel pedal with mud or oil stuck to your shoes, your foot may slip and this may cause a serious accident.
  • Page 23 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a genuine DOOSAN part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.
  • Page 24 • Slow down if it is necessary when traveling through rough terrain. • When driving machine, avoid obstacles excessive rough terrain. Keep the machine on terrain where working and traveling conditions are good. • Remove any large rocks or obstacles. •...
  • Page 25 Fuel, Oil and Hydraulic Fluid Fire Hazards Fuel, oil and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable and can be hazardous. Always strictly observe the following. Add fuel, oil, antifreeze and hydraulic fluid to the machine only in a well ventilated area.
  • Page 26 Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your health if it is inhaled. Materials containing asbestos fiber can be present on work site. Breathing air that contains asbestos fiber can ultimately cause serious or fatal lung damage. To prevent lung damage from asbestos fiber, observe following precautions: •...
  • Page 27 Reinstallation, recertification and/or replacement of the system may be necessary. Contact your DOOSAN distributor for available safety guards and/or recommendations to prevent danger of getting hit by objects that could strike the operator's cabin. Make sure that all other work site crew members are kept well away from the excavator and safe from possible hazards.
  • Page 28 Attachment Precautions Option kits are available through your dealer. Contact DOOSAN for information on available one-way (single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because DOOSAN cannot anticipate, identify or test all the attachments that owners may wish to install on their machines, please contact DOOSAN for authorization and approval of attachments, and their compatibility with optional kits.
  • Page 29 Indoor Ventilation Engine exhaust gases can cause fatal accidents, and unconsciousness, loss of alertness, judgment and motor control and serious injury. Make sure there is adequate ventilation before starting the engine in any enclosed area. You should also be aware of open windows, doors or ductwork where exhaust may be carried, or blown by the wind, exposing others to danger.

  • Page 30: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make sure the ground surface is as hard and horizontal as possible before carrying out operations.
  • Page 31 Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground collapses, the machine could fall or tip over resulting in serious injury or death. Remember that soil after heavy rain, blasting or after earthquakes, is weakened.
  • Page 32 Engine Starting Walk around your machine before getting in the operator's cabin. Look for evidence of leaking fluid, loose fasteners, misaligned assemblies or any other indications of possible equipment hazard. All equipment covers and machinery safety guards must be in place, to protect against injury while the machine is being operated.
  • Page 33 Before Operating Machine If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions.

  • Page 34: Machine Operation

    MACHINE OPERATION When Swinging or Changing Direction of Travel Before operating the machine or the work equipment, always observe the following precautions to prevent serious injury or death. • Start and operate the machine only while seated. • When changing travel direction from forward to reverse or from reverse to forward, reduce speed early and stop the machine before changing travel HAOA190L...
  • Page 35 When traveling on rough ground, travel at low speed, and avoid sudden changes in direction. Always keep to the permissible water depth. Permissible water depth is to the centerline of the upper track rollers. When traveling over bridges or structures on private land, check first that the bridge or structure can withstand the weight of the machine.
  • Page 36 Prohibited Operations Do not dig the work face under an overhang. This may cause the overhang to collapse and fall on top of the machine. FG012408 Figure 19 Do not carry out deep digging under the front of the machine. The ground under the machine may collapse and cause the machine to fall.
  • Page 37 Precautions for Operation Be careful not to mistakenly travel too close to the edge of a cliff. Use the machine only for its main purpose. Using it for other purposes will cause failures. To ensure a good view, always do the following: •...
  • Page 38 always contact the power utility company directly and work out a safety plan with them. Operate Carefully on Snow, Ice and in Very Cold Temperatures In icy cold weather avoid sudden travel movements and stay away from even slight slopes. The machine could skid off to one side very easily.
  • Page 39 Parking Machine Avoid making sudden stops, or parking the machine wherever it happens to be at the end of the workday. Plan so the excavator will be on firm, level ground away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff.
  • Page 40 Precautions for Traveling in Reverse Backing up is potentially dangerous because of restricted visibility. Use a signalman when backing up. • Watch for people nearby. • Use horn or other signal to warn people nearby. • Keep windows, mirrors and headlights clean and good repair at all times.

  • Page 41: Maintenance

    OSHA certified lockout device when performing inspection and a length of chain or cable to keep the safety lever in the fully lowered, nonactive position. Warning tags, for controls are available from DOOSAN 190-00695A distributors. FG012195...
  • Page 42 Proper Tools Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause personal injury. There is a danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness. HDO1037L Figure 31 Use of Lighting...
  • Page 43 Fire Prevention and Explosion Prevention All fuels, most lubricants and some coolant mixtures are flammable. Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire. Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons.
  • Page 44 Burn Prevention When checking the radiator coolant level, shut down engine, let the engine and radiator cool down, then check the coolant recovery tank. If the coolant level in the coolant recovery tank is near the upper limit, there is enough coolant in the radiator. Loosen the radiator cap gradually to release the internal pressure before removing the radiator cap.
  • Page 45 Welding Repairs CAUTION When you connect or disconnect connectors between ECU and Engine or connector between ECU and the machine, always disconnect the source power to protect damage of the ECU. If you don't observe this procedure, the ECU would be damaged or the engine would operate abnormally.
  • Page 46 Warning for Counterweight and Front Attachment Removal DANGER DOOSAN warns any user, that removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
  • Page 47 Precautions for Removal, Installation, and Storage of Attachments Before starting removal and installation of attachments, decide on the team leader. Do not allow anyone except the authorized workers close to the machine or attachment. Place attachments that have been removed from the machine in a safe place so they do not fall.
  • Page 48 In particular, if the machine is used when there are still problems with the brake or work equipment systems, it may lead to serious injury. If necessary depending on the type of failure, please contact your DOOSAN distributor for repairs. Track Excavator Safety SP001614 Page 40...
  • Page 49 Precautions with High-pressure Lines, Tubes and Hoses When inspecting or replacing high-pressure piping or hoses, check to verify that pressure has been released from the circuit. Failure to release the pressure may lead to serious injury. Always do the following: •...
  • Page 50 Cabin Tilting The machine has a tilting cabin for maintenance. If it is necessary to work or look under cabin, use following procedure. Fully extend arm and boom, and rest bucket on ground. Shut down engine and "LOCK" left stand. Remove two nuts and plain washers from rear floor.
  • Page 51 When cabin is raised to its proper angle, lower safety bar (4) and secure it to the main frame. WARNING Make sure that safety bar is secured before operating. Do not replace tilting mechanism components with cabin tilted. (This may result in machine damage or personal injuries.) FG012421 Figure 47...

  • Page 52: Battery

    BATTERY Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following: • Do not smoke or bring any flame near the battery. •...
  • Page 53 Boost Starting or Charging Engine Batteries If any mistake is made in the method of connecting the booster cables, it may cause an explosion or fire. Always do the following: • Turn off all electrical equipment before connecting leads to the battery. This includes electrical switches on the battery charger or boost starting equipment.

  • Page 54: Towing

    Shackle • If the engine on the problem machine will not start or there is a failure in the brake system. always contact your DOOSAN distributor. Towing Wire FG000669 • Never go between the towing machine and the Figure 51 towed machine during the towing operation.

  • Page 55: Shipping And Transportation

    SHIPPING AND TRANSPORTATION Obey State and Local Over-the-Road Regulations Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.
  • Page 56 Track Excavator Safety SP001614 Page 48...
  • Page 57 Specifications...
  • Page 59 SP001615 SPECIFICATION FOR DX60RSP001615 Specification for DX60R Edition 1 Specification for DX60R SP001615 Page 1...
  • Page 60 MEMO Specification for DX60R SP001615 Page 2...
  • Page 61 Table of Contents Specification for DX60R Safety Precautions..........5 Applicable Models ..........5 General Description ..........7 Component Locations .......... 8 Overall Dimensions ..........10 Working Range ........... 12 Standard Specifications ........14 Engine Performance Curves ......15 Approximate Weight of Workload Materials ..18 Performance Tests ..........
  • Page 62 MEMO Specification for DX60R SP001615 Page 4...
  • Page 63 Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Specification for DX60R SP001615 Page 5...
  • Page 64 Specification for DX60R SP001615 Page 6...
  • Page 65 The excavator has three main component sections: • The Upper Turntable • The Lower Undercarriage and Track Frames • The Excavator Front-end Attachment The following illustration identifies main components and their locations. (See Figure 1 on page -8.) Specification for DX60R SP001615 Page 7...
  • Page 66 COMPONENT LOCATIONS FG012434 Figure 1 Specification for DX60R SP001615 Page 8...
  • Page 67 Boom Swing Cylinder Blade Cylinder Center Joint Track Guide Control Valves Idler Swing Bracket Track AdujsterIdler Boom Cylinder Battery Boom Upper Roller Arm Cylinder Lower Roller Travel Motor Bucket Cylinder Track Link and Shoe Specification for DX60R SP001615 Page 9...

  • Page 68: Overall Dimensions

    OVERALL DIMENSIONS FG012609 Figure 2 Specification for DX60R SP001615 Page 10...
  • Page 69 1,904 mm (6' 3") 1,030 mm (3' 5") 927 mm (3' 0") 2,546 mm (8' 4") 319 mm (1' 1") 584 mm (1' 11") 400 mm (1' 4") 1,580 mm (5' 2") 1,980 mm (6' 6") Specification for DX60R SP001615 Page 11...

  • Page 70: Working Range

    Digging too far underneath the excavator when soil conditions are wet, loose or unstable can collapse ground support, which could cause injury and/or equipment damage. FG013195 Figure 3 Specification for DX60R SP001615 Page 12...
  • Page 71 Max. Depth to 8 ft Line 3,320 mm (10' 11") 3,770 mm (12' 4") Min. Radius 8 ft Line 1,115 mm (3' 8") 1,050 mm (3' 5") Min. Digging Reach 485 mm (1' 7") 0 mm (0' 0") Specification for DX60R SP001615 Page 13...

  • Page 72: Standard Specifications

    Shoe width 400 mm (1' 4") Track Tumbler distance 1,990 mm (6' 7") Lever control type Hydraulic pilot Control Lever pattern Fuel tank 78ℓ Tank Hydraulic tank 65ℓ Ground pressure 0.34 kg/cm (0.034 MPa) Specification for DX60R SP001615 Page 14...

  • Page 73: Engine Performance Curves

    30 (41) (221) 25 (34) (206) 20 (27) (191) 15 (20) (177) B.S.F.C 10 (14) (162) 5 (7) (147) 1,000 1,200 1,800 2,000 1,400 1,600 2,200 2,400 2,600 g/PSh Engine Speed (rpm) FG013211 Figure 4 Specification for DX60R SP001615 Page 15...
  • Page 74 Oil Grade API class CF, SAE grade 10W30 Oil Pump Trochoid pump Oil Filter Paper element Lubrication liter 11.6 Max. System Oil Capacity liter Effective. At rated output kgf/cm Oil Pressure At low idle kgf/cm Specification for DX60R SP001615 Page 16...
  • Page 75 Intial maximum restrictions: 12.7 (1,300 mmAq). Starter 12V-3.0kW Starting Battery 130E41 System Starting Aid Air heater 500W Generator 12V-6A Engine Color Black Applied Regulation EPA Intermediate Tier 4, and EC stage 3A. Specification for DX60R SP001615 Page 17...

  • Page 76: Approximate Weight Of Workload Materials

    Earth, loamy, DRY, loose --------------------- --------------------- (2,025 lb/yd 1,522 kg•m Earth, DRY, packed --------------------- --------------------- (2,565 lb/yd 1,762 kg•m Earth, WET, muddy --------------------- --------------------- (2,970 lb/yd Gypsum, calcined, 961 kg•m --------------------- --------------------- (heated, powder) (1,620 lb/yd Specification for DX60R SP001615 Page 18...
  • Page 77 1,522 kg•m Sand, DRY, loose --------------------- --------------------- (2,565 lb/yd 1,922 kg•m Sand, WET, packed --------------------- --------------------- (3,240 lb/yd 1,362 kg•m Shale, broken --------------------- --------------------- (2,295 lb/yd 529 kg•m Sulfur, broken --------------------- --------------------- (1,620 lb/yd Specification for DX60R SP001615 Page 19...

  • Page 78: Performance Tests

    2-speed 14.8 ± 1.0 1-speed 34.9 ± 2.0 Travel Speed 20 m (66 ft) 2-speed 18.6 ± 1.5 1-speed mm (in) 300 (11.8) Travel Deviation 20 m (66 ft) 2-speed mm (in) 300 (11.8) Specification for DX60R SP001615 Page 20...

  • Page 79: Excavator Performance Standards

    Prepare the excavator for travel speed tests by extending all hydraulic cylinders - boom, arm and bucket - to the fully extended position, shown in Figure 5.* 0.4 m ~ 0.5 m FG013212 Figure 5 Specification for DX60R SP001615 Page 21...
  • Page 80 (Figure 1) A greater amount of deviation is allowed with the travel control set for 2-speed. Rate of Travel Max. Distance 1-speed 300 mm (5.9 in) 2-speed 300 mm (5.9 in) Specification for DX60R SP001615 Page 22...

  • Page 81: Swing Speed And Deceleration Force Test

    Record how far the turntable drifts past the stop point, measuring the distance between paint marks. Maximum distance should be less than 260 mm (10-1/4"). Reference Description Number Start Swing 90° Swing Swing Force FG013218 Swing Stop Figure 7 Specification for DX60R SP001615 Page 23...

  • Page 82: Cylinder Performance Tests

    2.2 ± 0.3 sec Boom Down 2.0 ± 0.3 sec Arm Crowd 2.2 ± 0.3 sec Arm Dump 2.5 ± 0.3 sec Bucket Crowd 2.3 ± 0.3 sec Bucket Dump 3.6 ± 0.3 sec Specification for DX60R SP001615 Page 24...
  • Page 83 Record the number of seconds it takes the crawler shoe to make 3 full rotations, during both 1-speed and 2-speed operation. Operation Basic Value 1-speed 28.36 ± 1.5 sec 2-speed 16.24 ± 1.0 sec Specification for DX60R SP001615 Page 25...
  • Page 84 Specification for DX60R SP001615 Page 26...
  • Page 85 General Maintenance...
  • Page 87 SP000016 GENERAL MAINTENANCE PROCEDURES SP000016 General Maintenance Procedures Edition 1 General Maintenance Procedures SP000016 Page 1...
  • Page 88 MEMO General Maintenance Procedures SP000016 Page 2...
  • Page 89 Table of Contents General Maintenance Procedures Safety Precautions..........5 Applicable Models ..........5 Welding Precautions and Guidelines ....6 Hydraulic System - General Precautions....8 Maintenance Service and Repair Procedure ..9 General Precautions............9 Hydraulic System Cleanliness and Oil Leaks..10 Maintenance Precautions for Hydraulic System Service..............
  • Page 90 MEMO General Maintenance Procedures SP000016 Page 4...

  • Page 91: General Maintenance Procedures

    SAFETY PRECAUTIONS CAUTION Follow all safety recommendations and safe shop practices outlined in front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling the load.

  • Page 92: Welding Precautions And Guidelines

    If repairs are performed incorrectly, structural weakening or other damage to the machine (that is not always readily visible) could be caused. Always consult DOOSAN After Sales Service Distributor before welding on integral components (loader arm, frames, car body, track frames, turntable, attachment, etc.) of the machine.
  • Page 93 CAUTION Observe the following safety precautions: Use extra caution and adequate safety shielding when welding near fuel and oil tanks, batteries, hydraulic piping lines or other fire hazards. Never weld when the engine is running. Battery cables must be disconnected before the welding procedure is started.

  • Page 94: Hydraulic System - General Precautions

    HYDRAULIC SYSTEM - GENERAL PRECAUTIONS Always maintain oil level in the system at recommended levels. Assemblies that operate under heavy loads, at high-speed, with extremely precise tolerances between moving parts - pistons and cylinders, or shoes and swash plates, for example - can be severely damaged if oil supply runs dry.
  • Page 95 Hydraulic system operating under conditions such as repetitive cycling, heavy workloads, fluid circulating under high-pressure, make it extremely critical that dust, grit or any other contamination be kept out of the system. Observe fluid and filter change maintenance interval recommendations and always preclean any exterior surface of the system before it is exposed to air.

  • Page 96: Maintenance Service And Repair Procedure

    MAINTENANCE SERVICE AND REPAIR PROCEDURE General Precautions Fluid level and condition should always be checked whenever any other maintenance service or repair is being performed. NOTE: If the unit is being used in an extreme temperature environment (in subfreezing climates or in high temperature, high humidity tropical conditions), frequent purging of moisture condensation from the hydraulic reservoir drain tap should be a regular and...

  • Page 97: Hydraulic System Cleanliness And Oil Leaks

    HYDRAULIC SYSTEM CLEANLINESS AND OIL LEAKS Maintenance Precautions for Hydraulic System Service Whenever maintenance, repairs or any other troubleshooting or service is being performed, it's important to remember that the hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating fluid - must be protected from contamination.

  • Page 98: Oil Leakage Precautions

    Oil Leakage Precautions Oil that is visibly seeping from joints or seals should always serve as a "red flag" alarm. Leaks must alert the machine operator and maintenance crew that air, water and dirt have an open, free passageway through which to enter the circuit.

  • Page 99: Cleaning And Inspection

    CLEANING AND INSPECTION General Guidelines All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign material enters unit being assembled. Even minute particles can cause malfunction of close fitting parts such as thrust bearing, matched parts, etc.

  • Page 100: Bearing Inspection

    avoid cutting or scratching. Curling under of any seal lip will seriously impair its efficiency. Apply a thin coat of loctite #120 to outer diameter, of metal casing, on oil seals to assure an oil tight fit into retainer. Use extreme care not to get loctite on lips of oil seals.
  • Page 101 bearing alone without replacing the mating cup or the cone at the same time. After inspection lightly coat the bearing and related parts with oil and wrap in a clean lintless cloth or paper and protect them from moisture and other foreign materials until installation. It is also important to inspect the bearing housing and/or shaft for grooved, galled or burred conditions that indicate the bearing has been turning in its housing or on its shaft.
  • Page 102 Replace bearing. Figure 4 Galling Metal smears on roller ends because of overheating, lubricant failure or overload. Replace bearing - check seals and check for proper lubrication. Figure 5 Abrasive Step Wear Pattern on roller ends caused by fine abrasives. Clean all parts and housings, check all parts and housings, check seals and bearings and replace if leaking, rough or noisy.
  • Page 103 Etching Bearing surfaces appear gray or grayish black in color with related etching away of material usually at roller spacing. Replace bearings - check seals and check for proper lubrication. Figure 7 Misalignment Outer race misalignment because of foreign object. Clean related parts and replace bearing.
  • Page 104 Fatigue Spalling Flaking of surface metal resulting from fatigue. Replace bearing - clean all related parts. Figure 10 Brinelling Surface indentations in raceway caused by rollers either under impact loading or vibration while the bearing is not rotating. Replace bearing if rough or noisy. Figure 11 Cage Wear Wear around outside diameter of cage and roller pockets...
  • Page 105 Abrasive Roller Wear Pattern on races and rollers caused by fine abrasives. Clean all parts and housings, check seals and bearings and replace if leaking, rough or noisy. Figure 13 Cracked Inner Race Race cracked because of improper fit, cocking or poor bearing seat.
  • Page 106 Frettage Corrosion set up by small relative movement of parts with no lubrication. Replace bearing. Clean all related parts. Check seals and check for proper lubrication. Figure 16 Heat Discoloration Heat discoloration can range from faint yellow to dark blue resulting from overload or incorrect lubrication.
  • Page 107 SP000813 STANDARD TORQUESSP000813 Standard Torques Edition 1 Standard Torques SP000813 Page 1...
  • Page 108 MEMO Standard Torques SP000813 Page 2...
  • Page 109 Table of Contents Standard Torques Safety Precautions..........5 Applicable Models ..........5 Torque Values for Standard Metric Fasteners..6 Torque Values for Standard U.S. Fasteners ..7 Type 8 Phosphate Coated Hardware ....9 Torque Values for Hose Clamps......10 Torque Values for Split Flanges ......
  • Page 110 MEMO Standard Torques SP000813 Page 4...

  • Page 111: Standard Torques

    SAFETY PRECAUTIONS CAUTION Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load.

  • Page 112: Torque Values For Standard Metric Fasteners

    TORQUE VALUES FOR STANDARD METRIC FASTENERS NOTE: The units for the torque values are kg•m (ft lb). Grade Dia. x Pitch (mm) 10.9 12.9 (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K) 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48...

  • Page 113: Torque Values For Standard U.s. Fasteners

    TORQUE VALUES FOR STANDARD U.S. FASTENERS S.A.E. Bolt Head Type Description Grade Marking WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD. 1 OR 2 Low or Medium Carbon Steel Not Heat Treated. WILL HAVE THREE RADIAL LINES. Quenched and Tempered Medium Carbon Steel. WILL HAVE 6 RADIAL LINES.
  • Page 114 The following General Torque Values must be used in all cases where SPECIAL TORQUE VALUES are not given. NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values should be increased 1/3 for nonlubricated (dry) threads. Heat Treated Material Grade 5 and Grade 8 Grade 5 Grade 8 Thread Size...

  • Page 115: Type 8 Phosphate Coated Hardware

    TYPE 8 PHOSPHATE COATED HARDWARE This chart provides tightening torque for general purpose applications using original equipment standard hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTITUTE. In most cases, original equipment standard hardware is defined as Type 8, coarse thread bolts and nuts and thru hardened flat washers (Rockwell "C"...

  • Page 116: Torque Values For Hose Clamps

    TORQUE VALUES FOR HOSE CLAMPS The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator, air cleaner, operating lever boots, hydraulic system, etc.). Torque Radiator, Air Cleaner, Boots, Etc. Hydraulic System Clamp Type And Size Kilogram Meter Inch Pounds Kilogram Meter...

  • Page 117: Torque Wrench Extension Tools

    TORQUE WRENCH EXTENSION TOOLS Very large diameter, high grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force to achieve recommended tightening torque values. Common problems that could occur as a result are: • Recommended torque exceeds the measuring capacity of the torque wrench.

  • Page 118: Other Uses For Torque Wrench Extension Tools

    NOTE: The formula assumes that there is no added deflection or "give" in the joint between the extension torque wrench. Readings also inaccurate: • If the extension itself absorbs some of the tightening force and starts to bend or bow out. •...

  • Page 119: Tightening Torque Specifications (Metric)

    Use the information on this page as a general guide in selecting specific formulas that will meet the particular requirements of individual assembly installations. DOOSAN does not specifically endorse a specific manufacturer or brand name but the following table of "Loctite" applications is included for which cross-references to other makers' products should also be widely available.
  • Page 120 I. "Loctite" Fastener Adhesives Breakaway Cure Product Application Color Removal Strength (in lb) of Sealer Alone Low strength for 6 mm (1/4") or Purple Hand tools smaller fasteners. Medium strength for 6 mm (1/4") and 242 or 243 Blue Hand tools larger fasteners.
  • Page 121 IV. "Loctite" retaining compounds Product Application Color Notes For bushings, sleeves, press fit Use Locquic "N" primer for increased bond bearings, splines and collars. For Green strength and all cold temperature gaps to 0.0002 mm (0.005"), applications. temperatures to 121°C (250°F). For high temperatures to 232°C Green Same as 609, above.
  • Page 122 Standard Torques SP000813 Page 16...
  • Page 123 Upper Structure...
  • Page 125 SP001623 CABIN SP001623 Cabin Edition 1 Cabin SP001623 Page 1...
  • Page 126 MEMO Cabin SP001623 Page 2...
  • Page 127 Table of Contents Cabin Safety Precautions..........5 Applicable Models ..........5 Removal..............6 Installation ............10 Cabin SP001623 Page 3...
  • Page 128 MEMO Cabin SP001623 Page 4...

  • Page 129: Safety Precautions

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up Cabin SP001623 Page 5...

  • Page 130: Removal

    REMOVAL CAUTION Avoid disassembling cabin if there are strong wind gusts, which could catch large surface area of cabin shell and push it sideways during lift. Park on firm and level ground. Lock Lower front attachment (bucket) to ground. Unlock Shut down engine.
  • Page 131 12. Tilt up cabin. Remove a bolt (Figure 2). Disconnect pilot hoses as required. Tilt down cabin. NOTE: Please refer to cabin tilting. NOTE: Be careful about hydraulic oil leak. FG013471 Figure 2 13. Remove seven M8 bolts Then open side cover of main frame (Figure 3).
  • Page 132 15. First, separate the main harness connector (A, Figure 6). Separate the left stand harness (B, Figure 7) and right stand harness (C, Figure 8). After separating the air conditioner box cover (E, Figure 9) under the seat, separate the harness passing next to the air conditioner box (D, Figure 10).
  • Page 133 FG011065 Figure 10 17. Remove six bolts (M10) and washer, a nut (M10), two nuts (M16) and washers (Figure 11). FG013819 Figure 11 18. Install sling on four places above cabin with proper device for lifting (Figure 12). NOTE: The weight of cabin is about 480 kg (1,058.2 lb). 19.

  • Page 134: Installation

    INSTALLATION Install sling on four places above cabin with proper device for lifting. NOTE: The weight of cabin is about 480 kg (1,058.2 lb). Lower cabin into position on floor. FG013819 Figure 13 Install six bolts (M10) and washer, a nut (M10), two nuts (M16) and washers (Figure 14).
  • Page 135 Once cabin is mounted to floor, unhook lifting device. Connect the main harness, the harness of stand of both ends and the harness passing next to the air conditioner box in that order (A ~ D, Figure 16 ~ Figure 19). FG013820 Figure 16 FG013821...
  • Page 136 Install seven M8 bolts Then open side cover (3) of main frame (Figure 21). Tilt up cabin. Install a bolt (Figure 20). Connect all hydraulic hoses. Tilt down cabin. NOTE: Please refer to cabin tilting. NOTE: Be careful about hydraulic oil leak. FG013471 Figure 20 10.
  • Page 137 SP001624 SWING BEARING SP001624 Swing Bearing Edition 1 Swing Bearing SP001624 Page 1...
  • Page 138 MEMO Swing Bearing SP001624 Page 2...
  • Page 139 Table of Contents Swing Bearing Safety Precautions..........5 Applicable Models ..........5 Swing Bearing Maintenance ........ 6 Operating Recommendation........... 6 Measuring Swing Bearing Axial Play ......6 Measuring Bearing Lateral Play ........6 Swing Bearing Basic Operation ........7 Rebuilding Swing Bearing..........7 Swing Bearing SP001624 Page 3...
  • Page 140 MEMO Swing Bearing SP001624 Page 4...

  • Page 141: Swing Bearing

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Swing Bearing SP001624 Page 5...

  • Page 142: Swing Bearing Maintenance

    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.

  • Page 143: Swing Bearing Basic Operation

    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.
  • Page 144 Lift outer ring and check that inner ring can move freely. See Figure 5, if not, replace seal (3, Figure 4). Figure 5 Turn inner ring and use magnet bar (1, Figure 6) to remove steel balls (2). Figure 6 Turn inner ring and use wire (1, Figure 7) to remove retainers (2).
  • Page 145 Lower Structure and Chassis...
  • Page 147 SP001625 TRACK ASSEMBLY SP001625 Track Assembly Edition 1 Track Assembly SP001625 Page 1...
  • Page 148 MEMO Track Assembly SP001625 Page 2...
  • Page 149 Table of Contents Track Assembly Safety Precautions..........5 Applicable Models ..........5 Tracks ..............6 Specification and Construction ........6 Track Tension ............7 Cleaning and Inspection (Wear Limits and Tolerances)............9 Rubber Track Features ........... 9 Steel Tracks..............11 Track Frame Spring............
  • Page 150 Reassembly..............26 Lower Roller............27 Steel Track ..............27 Rubber Track ..............28 Disassembly..............29 Reassembly..............29 Upper Roller ............30 Parts List................ 30 Disassembly..............31 Reassembly..............31 Sprocket ............. 32 Disassembly..............32 Reassembly..............32 Track Assembly SP001625 Page 4...

  • Page 151: Track Assembly

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Track Assembly SP001625 Page 5...

  • Page 152: Tracks

    TRACKS Specification and Construction Steel Tracks Figure 1 Track Frame Track Frame Lower Roller Track Adjuster FG013225 Figure 2 Track Assembly SP001625 Page 6...

  • Page 153: Track Tension

    TRACK TENSION WARNING Safely measuring track tension requires two people. 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 won't move or shift position during service.
  • Page 154 NOTE: For machines with steel tracks, checking and adjustment steps and clearance are the same. Figure 4 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 1 complete turn from the fully tightened down position.

  • Page 155: Cleaning And Inspection (Wear Limits And Tolerances)

    CLEANING AND INSPECTION (WEAR LIMITS AND TOLERANCES) CAUTION Refer to the "Welding Precautions and Guidelines" information in "General Maintenance Procedures" section general recommendations specific safety precautions, before starting any lower travel frame component rebuilding procedure. The tables that follow provide factory specified dimensional limits condition, recommended...
  • Page 156 Figure 9 Item DX60R 5,365 ± 10 mm Distance Between Centers of Tracks (211.22 ± 0.39 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°...

  • Page 157: Steel Tracks

    Steel Tracks FG010287 Figure 11 Item Standard Limits Remarks 135 mm 137 mm Link Pitch (5.32 in) (5.4 in) 70.0 mm 67.5 mm Link Height Build up or replace. (2.75 in) (2.66 in) 14 ±1 mm 9.0 mm Track Height Build up or replace.

  • Page 158: Track Frame Spring

    Track Frame Spring FG013227 Figure 12 Item Criteria Remarks Limit Bending 5 (Overall length of track frame) 10 (Distortion between left and right Deformed frame 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...

  • Page 159: Idler

    Idler Steel Tracks FG010668 Figure 13 Item Standard Limits Remarks 365.0 mm Diametre of Flange (14.37 in) 328 mm 316 mm Diametre of Link Repair (12.91 in) (12.44 in) 98 mm Front Width (3.86 in) 46.6 mm Flange Width (1.83 in) 25.6 mm 31.1 mm Thread width...

  • Page 160: Spring Specifications

    Spring Specifications Figure 14 Designation Dimensions No. of Active Coils Total No. of Coils 75.5 kgf/mm Spring Constant (4,227 lb/in) 2,600.0 kg Set Load (5,730 lb) 5,780.0 kg Compressive Load (12,740 lb) 303.6 mm Free Length: LO (11.95 in) 227.0 mm Minimum Closed Length (8.94 in) 128.0 mm...

  • Page 161: Lower Roller

    LOWER ROLLER Steel Track Figure 15 Item Standard Limits Remarks 120.0 mm Body Length (4.72 in) 46.6 mm 40.6 mm Flange Width Repair (1.83 in) (1.59 in) 140 mm Diameter of Flange (5.5 in) 110 mm 102 mm Diameter of Link Repair (4.33 in) (4.02 in)

  • Page 162: Rubber Track

    Rubber Track Figure 16 Item Standard Limits Remarks 110.0 mm Body Length (4.33 in) 46.6 mm 40.6 mm Flange Width Repair (1.83 in) (1.59 in) 144 mm Diameter of Flange (5.11 in) 100 mm 92 mm Diameter of Link Repair (3.93 in) (3.62 in) Tolerance...

  • Page 163: Upper Roller

    UPPER ROLLER Figure 17 Item Standard Limits Remarks 110 mm Body Length (4.33 in) 46.6 mm 40.6 mm Flange Width Repair (1.83 in) (1.59 in) 130 mm Diameter of Flange (5.11 in) 100 mm 92 mm Diameter of Link Repair (3.93 in) (3.62 in) Tolerance...

  • Page 164: Sprocket

    SPROCKET FG010671 Figure 18 Item Standard Limits Remarks 42.5 mm 36.0 mm Sprocket Tooth Width Build up or replace (1.67 in) (1.42 in) Sprocket Dedendum ø377 mm ø411.0 mm Build up or replace Diameter (14.84 in) (16.18 in) Mounting Bolt Tightening 18 kg•m M14 x 2.0 Torque...

  • Page 165: Track Removal And Installation

    TRACK REMOVAL AND INSTALLATION Track Removal The track removal is a dangerous operation. It must be done with machine jacked up on one side resting on adequate blocking. Never move machine during removal operation. Be careful not to tipped machine over. WARNING The track adjusting mechanism is under very high-pressure.

  • Page 166: Track Installation

    Track Removal Lift machine on one side using front attachment and install wood blocks under machine. Steel Tracks Remove master pin (1) from linkage by turning it to idler side, and then remove track (2). Figure 21 Rubber Tracks Retract idler all the way, and remove rubber track from idler using a steel bar.

  • Page 167: Replacement Of Rubber Tracks With Steel Tracks

    Replacement of Rubber Tracks with Steel Tracks Remove tracks and idlers. Loosen track roller mounting bolt to remove track roller. Figure 24 Mount track roller for steel track. NOTE: Be sure to install a washer for steel track. Washer for Steel Crawler FG008482 Figure 25 Install guide plate.

  • Page 168: Replacement Of Steel Tracks With Rubber Tracks

    Replacement of Steel Tracks with Rubber Tracks Remove steel tracks and track rollers. Remove idlers for steel track. Figure 27 Install track rollers for rubber tracks. NOTE: Nut tightening torque: 34.50 kg•m (250 ft lb) Washer for Steel Crawler FG008482 Figure 28 Remove guide plate.

  • Page 169: Idler

    IDLER Parts List FG011233 Figure 30 Reference Reference Description Description Number Number Idler O-ring Shaft Support Plug Bushing F/Seal Track Assembly SP001625 Page 23...

  • Page 170: Disassembly

    Disassembly Refer to "Track Disassembly" to remove track and idler assembly. Remove spring pin (7) from support (3). Remove support (3) from shaft (2). Remove O-ring (6) using a screwdriver (-). • Once removed, O-ring (6) should not be reused. Remove floating seal (5), bushing (4), shaft (2) and plug (8).

  • Page 171: Track Tension Adjusting Cylinder

    TRACK TENSION ADJUSTING CYLINDER Parts List FG013472 Figure 31 Reference Reference Description Description Number Number Flange U-packing Cylinder Back up Ring Dust Ring Nok DSI-50 Spring Valve Split Pin Track Assembly SP001625 Page 25...

  • Page 172: Disassembly

    Disassembly NOTE: Be sure to use a special tool when removing spring. NOTE: Take care as spring may pop out. Remove tracks and idlers. Use a press to relieve spring force. Remove split pin (10) and nut (9). Remove spring (4) from tension cylinder (2). Remove track tension valve (5) from tension rod (3).
  • Page 173 LOWER ROLLER Steel Track Parts List FG013473 Figure 32 Reference Reference Description Description Number Number Roller Floating Seal Shaft O-ring Collar Retaining Ring Bushing Plug PT1/8 Track Assembly SP001625 Page 27...
  • Page 174 Rubber Track Parts List FG011235 Figure 33 Reference Reference Description Description Number Number Body Collar Shaft Snap Ring Bushing Plug F/Seal O-ring Track Assembly SP001625 Page 28...
  • Page 175 Disassembly Remove track. Loosen nut (M24) and remove track roller from track frame. Remove C-type stopper ring (7) and plug (8) then Collar (6). Remove floating seal (4) and bushing (3). Use a screwdriver (-), to take out O-ring (5). •...
  • Page 176 UPPER ROLLER Parts List FG013473 Figure 34 Reference Reference Description Description Number Number Roller Floating Seal Shaft O-ring Collar Retaining Ring Bushing Plug PT1/8 Track Assembly SP001625 Page 30...
  • Page 177 Disassembly Remove track. Loosen nut (M24) and remove upper roller from track frame. Remove pin and collar. Use a screwdriver (-) to take out O-ring (6). NOTE: Once removed, oil seal should not be reused. Remove floating seal (5) and bushing (4) then shaft (2) from body.
  • Page 178 SPROCKET Disassembly Remove tracks. Remove sprocket clamping bolt (1) and sprocket (2) from travel motor. Reassembly Install sprocket to travel motor and tighten clamping bolt. FG008479 NOTE: Tightening torque: 11.50 kg•m (83 ft lb) Figure 35 Assembly tracks. Track Assembly SP001625 Page 32...
  • Page 179 Engine and Drive Train...
  • Page 181 SP001693 ENGINE SP001693 Engine Edition 1 Engine SP001693 Page 1...
  • Page 182 MEMO Engine SP001693 Page 2...
  • Page 183 Table of Contents Engine Safety Precautions..........7 Applicable Models ..........7 Safety..............8 Safety Precautions ............8 General Service Information ....... 31 Component Identification ..........31 Location of Labels............32 Function of Major Engine Components......33 Main Electronic Control Components and Features ..34 Function of Cooling System Components.....
  • Page 184 Measuring and Adjusting Valve Clearance....123 Crankshaft and Camshaft Components...... 128 EGR System ..............160 Fuel System ............167 Before You Begin Servicing ........167 Introduction ..............170 Fuel System Specifications ......... 174 Special Service Tools..........174 Measuring Instruments..........175 Fuel System Diagram ..........
  • Page 185 Starter Motor..............223 Alternator ............235 Before You Begin Servicing ........235 Introduction ..............239 Alternator Specifications ..........239 Dynamo Specifications ..........239 Alternator Troubleshooting.......... 240 Alternator Components ..........242 Alternator Wiring Diagram........... 244 Alternator Standard Output ......... 245 Alternator..............246 Dynamo Component Location ........
  • Page 186 MEMO Engine SP001693 Page 6...

  • Page 187: Safety Precautions

    Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Engine SP001693 Page 7...

  • Page 188: Safety

    SAFETY MEMO Safety Precautions DANGER Scald Hazard! Never Remove the radiator cap if the engine is hot. Steam and hot engine coolant will spurt out and seriously burn you. Allow the engine to cool down before you attempt to remove the radiator cap. Tighten the radiator cap securely after you check the HAOA060L radiator.
  • Page 189 DANGER Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions. When you remove any fuel system component to perform maintenance (such as changing the fuel filter) place an approved container under the opening to catch the fuel. HDO1015I Never use a shop rag to catch the fuel.
  • Page 190 DANGER MEMO Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions. Only fill the fuel tank with diesel fuel. Filling the fuel tank with gasoline may result in a fire and will damage the engine. HDO1015I Never refuel with the engine running.
  • Page 191 DANGER Crush Hazard! When you need to transport an engine for repair, have a helper assist you to attach it to a hoist and load it on a truck. Never stand under a hoisted engine. If the hoist mechanism fails, the engine will fall on you, causing death or serious HDO1042L injury.
  • Page 192 DANGER MEMO Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions. Never use diesel fuel as a cleaning agent. Failure to comply will result in death or serious injury. HDO1015I Figure 11 DANGER Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions.
  • Page 193 WARNING Exhaust Hazard! Never operate the engine in an enclosed area such as a garage, tunnel, underground room, manhole or ship’s hold without proper ventilation. Never block windows, vents, or other means of ventilation if the engine is operating in an enclosed area. All internal ARO1770L combustion engines create carbon monoxide gas during Figure 14...
  • Page 194 Never check for a fuel leak with your hands. Always use a Figure 19 piece of wood or cardboard. Consult authorized DOOSAN dealer or DOOSAN after sales service if you have any questions or require more information. Failure to comply could result in death or serious injury.
  • Page 195 WARNING Shock Hazard! Turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the electrical system. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors. Always keep the FG009151 connectors and terminals clean. Figure 20 Failure to comply could result in death or serious injury.
  • Page 196 WARNING MEMO Burn Hazard! Keep your hands and other body parts away from hot engine surfaces such as the muffler, exhaust pipe, turbocharger (if equipped) and engine block during operation and shortly after you shut the engine down. These surfaces are extremely hot while the engine is operating and could seriously burn you.
  • Page 197 WARNING Never inject fuel toward you. Since the fuel is injected at high pressure from the nozzle, it may penetrate the skin, resulting in injury. Never inject fuel toward a fire source. Atomized fuel is highly flammable and may cause a fire or burn skin. CAUTION Coolant Hazard! Wear eye protection and rubber gloves when you handle...
  • Page 198 If any oil pump component clearance exceeds its limit, the oil pump must be replaced as an assembly. CAUTION Only use diesel fuels recommended by DOOSAN for the best engine performance, to prevent engine damage and to comply with EPA / ARB warranty requirements.
  • Page 199 CAUTION Never hold the key in the START position for longer than 15 seconds or the starter motor will overheat. CAUTION Make sure the engine is installed on a level surface. If a continuously running engine is installed at an angle greater than 30°...
  • Page 200 If the ambient temperature is below +5°F (-15°C) the engine will be hard to start and the engine oil may not flow easily. Contact your authorized DOOSAN dealer or distributor if the engine will be operated outside of this standard temperature range.
  • Page 201 Always keep the oil level between the upper and lower lines on the oil cap / dipstick. CAUTION For maximum engine life, DOOSAN recommends that when shutting the engine down, you allow the engine to idle, without load, for five minutes. This will allow the engine...
  • Page 202 CAUTION MEMO Never engage the starter motor while the engine is running. This may damage the starter motor pinion and / or ring gear. CAUTION New Engine Break-in: On the initial engine start-up, allow the engine to idle for approximately 15 minutes while you check for proper engine oil pressure, diesel fuel leaks, engine oil leaks, coolant leaks, and for proper operation of the indicators and / or gauges.
  • Page 203 Figure 30 CAUTION If any indicator fails to illuminate when the key switch is in the ON position, see your authorized DOOSAN dealer or distributor for service before operating the engine. CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at the intervals indicated.
  • Page 204 CAUTION MEMO If the fuel filter / water separator is positioned higher than the fuel level in the fuel tank, water may not drip out when the fuel filter / water separator drain cock is opened. If this happens, turn the air vent screw on the top of the fuel filter / water separator 2-3 turns counterclockwise.
  • Page 205 CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub. Do not disassemble the fuel injection pump drive gear from the hub. Correct fuel injection timing will be very difficult or impossible to achieve.
  • Page 206 CAUTION MEMO If the engine coolant pump must be replaced, replace the engine coolant pump as an assembly only. Do not attempt to repair the engine coolant pump or replace individual components. CAUTION Use a new special O-ring between the engine coolant pump and the joint.
  • Page 207 IC regulator. This will corrode the conductor and result in battery over-charging (boiling) and charging malfunctions. Consult authorized DOOSAN dealer or distributor before using the equipment in such an environment or the warranty is voided. CAUTION...
  • Page 208 CAUTION MEMO Make sure that the combined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated in the Battery Cable Resistance chart in the Electric Wiring Section of this manual.
  • Page 209 CAUTION Never attempt to modify the engine’s design or safety features such as defeating the engine speed limit control or the diesel fuel injection quantity control. Modifications impair engine’s safety performance characteristics and shorten the engine’s life. Any alterations to this engine may void its warranty. Be sure to use genuine replacement parts.
  • Page 210 CAUTION MEMO Any part which is found defective as a result of inspection or ant part whose measured value does not satisfy the standard or limit must be replaced. CAUTION Any part determined to not meet the service standard or limit before the next service, as determined from the state of current rate of wear, should be replaced even though the part currently meets the service standard limit.

  • Page 211: General Service Information

    GENERAL SERVICE INFORMATION Component Identification Figure 31 Reference Reference Description Description Number Number Lifting Eye (Flywheel End) Intake Manifold Turbocharger* Fuel Filter Lifting Eye Fuel Inlet (Engine Cooling Fan End) Fuel Return to Fuel Tank Engine Coolant Pump Top Filler Port (Engine Oil) Engine Cooling Fan Rocker Arm Cover Crankshaft V-Pulley...

  • Page 212: Location Of Labels

    Location of Labels MEMO Figure 32 97/68/EC Emission Model Engine Nameplate EPA.ARB Certification Label Control Label On the top of the locker arm On the top of the locker arm On the top of the locker 4TNV98-E cover(flywheel end) cover(Center) arm cover(fan end) (Figure 32 right, 4) (Figure 32 right, 1)

  • Page 213: Function Of Major Engine Components

    Function of Major Engine Components Components Functions Air Cleaner The air cleaner prevents airborne contaminants from entering the engine. Since the air cleaner is application specific, it must be carefully selected by an application engineer. Periodic replacement of the air cleaner filter element is necessary. See “Periodic Maintenance Schedule”...

  • Page 214: Main Electronic Control Components And Features

    Main Electronic Control Components and Features MEMO Component/Feature Description Engine controller (E-ECU) Adjusts the rack position of the fuel injection pump depending on the speed command signal from the accelerator sensor, thus regulating the engine speed and power. The engine controller also regulates the opening of the EGR valve depending on the engine speed and power.
  • Page 215 Component/Feature Description Droop control Standard with VM series Reduces the engine speed by a certain percentage from no load to full (rated) load in steady state operation. The same percentage droop is maintained even when the load increases at any no-load speed. Isochronous Standard with CL series Offers a constant engine speed from no load to full load.

  • Page 216: Function Of Cooling System Components

    Function of Cooling System Components MEMO Components Functions Cooling System The TNV engine is liquid-cooled by means of a cooling system. The cooling system consists of a radiator, radiator cap, engine cooling fan, engine coolant pump, thermostat, and reserve tank. NOTE: That all cooling system components are required for proper engine operation.

  • Page 217: Diesel Fuel

    Poor quality fuel can reduce engine performance and / or cause engine damage. Fuel additives are not recommended. Some fuel additives may cause poor engine performance. Consult your DOOSAN representative for more information. The ash content must not exceed 0.01% by volume.
  • Page 218 FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels. DOOSAN approves the use of bio-diesel fuels that do not exceed a blend of 5% (by volume) of FAME with 95% (by volume) of approved mineral oil derived diesel fuel.
  • Page 219 Failure to comply will result in death or serious injury. CAUTION Only use diesel fuels recommended by DOOSAN for the best engine performance, to prevent engine damage and to comply with EPA / ARB warranty requirements.
  • Page 220 DANGER Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions. Before you operate the engine, check for fuel leaks. Replace rubberized fuel hoses every two years or every 2000 hours of engine operation, whichever comes first, even if the engine HDO1015I has been out of service.

  • Page 221: Engine Oil

    Select the oil viscosity based on the ambient temperature where the engine is being operated (Figure 37). DOOSAN does not recommend the use of engine oil "additives". Additional Technical Engine Oil Requirements: The engine oil must be changed when the Total Base Number (TBN) has been reduced to 2.0.
  • Page 222 Engine Oil Viscosity Select the appropriate engine oil viscosity based on the SAE 10W ambient temperature and use the SAE Service Grade Viscosity SAE 20W Chart in Figure 37. SAE 10W-30 SAE 15W-40 SAE 20 SAE 30 SAE 40 SAE 20W-50 -4 F 14 F 32 F...

  • Page 223: Engine Coolant

    Engine Coolant WARNING Exhaust Hazard! Never operate the engine in an enclosed area such as a garage, tunnel, underground room, manhole or ship’s hold without proper ventilation. Never block windows, vents, or other means of ventilation if the engine is operating in an enclosed area. All internal ARO1770L combustion engines create carbon monoxide gas during Figure 39...
  • Page 224 ALWAYS use a mix of coolant and water. NEVER use water only. Mix the coolant and water per the mixing instructions on the coolant container. Water quality is important to coolant performance. DOOSAN recommends that soft, distilled, demineralized water beused to mix with coolants.
  • Page 225 Filling Radiator with Engine Coolant Fill the radiator and reserve tank as follows. This procedure is for filling the radiator for the first time or refilling it after it is flushed. Note that a typical radiator is illustrated (Figure 42). Check to be sure the radiator drain plug is installed and tightened or the drain cock (1, Figure 42) is closed.

  • Page 226: Principal Engine Specifications

    Principal Engine Specifications 4TNV98-E Engine Model 4TNV98-E Version Type Vertical, 4-cycle water-cooled diesel engine Combustion System Direct Injection Aspiration Natural Aspiration No. of Cylinders Bore x Stroke 98 x 110 mm Displacement 3.319 L Continuous Rated Output 2,100 2,200 2,300 2,400 2,500 Max.

  • Page 227: Engine Service Standards

    Engine Service Standards Reference Inspection Item Standard Limit page See “Measuring and Adjusting Intake / Exhaust Valve All models 0.006 - 0.010 in. Valve Clearance except (0.15 - 0.25 mm) Clearance” on page -123 Fuel Injection See “Checking and Adjusting Fuel Injection Timing” on page -189 Timing Fuel Injection See “Test and Adjustment Specifications”...

  • Page 228: Tightening Torques For Standard Bolts And Nuts

    Tightening Torques for Standard Bolts and Nuts Use the correct amount of torque when you tighten the fasteners on the machine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure. CAUTION The tightening torque in the standard Torque Chart (see General Service Information section) should be applied...
  • Page 229 Nominal Thread Item x Pitch Tightening Torque Remarks Diameter 9 - 12 ft-lb (112 - 148 in.-lb, 12.7 - 16.7 N•m, 1.3 - 1.7 kgf•m) 14 - 19 ft-lb (173 - 225 in.-lb, 19.6 - 18.734 N•m, 2.0 - 3.5 kgf•m) Pipe Joint Bolt 18 - 25 ft-lb (24.5 - 34.3 N•m,...

  • Page 230: Periodic Maintenance

    PERIODIC MAINTENANCE Before You Begin Servicing DANGER Explosion Hazard! Never check the remaining battery charge by shorting out the terminals. This will result in a spark and may cause an explosion or fire. Use a hydrometer to check the remaining battery charge.
  • Page 231 DANGER Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions. Only fill the fuel tank with diesel fuel. Filling the fuel tank with gasoline may result in a fire and will damage the engine. HDO1015I Never refuel with the engine running. Figure 49 Wipe up all spills immediately.
  • Page 232 DANGER Fire And Explosion Hazard! Diesel fuel is extremely flammable and explosive under certain conditions. Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container. Hold the hose nozzle firmly against the side of HDO1015I the container while filling it.
  • Page 233 DANGER Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions. When you remove any fuel system component to perform maintenance (such as changing the fuel filter) place an approved container under the opening to catch the fuel. HDO1015I Never use a shop rag to catch the fuel.
  • Page 234 WARNING Exhaust Hazard! Never operate the engine in an enclosed area such as a garage, tunnel, underground room, manhole or ship°Øs hold without proper ventilation. Never block windows, vents, or other means of ventilation if the engine is operating in an enclosed area. All internal ARO1770L combustion engines create carbon monoxide gas during Figure 57...
  • Page 235 WARNING Sudden Movement Hazard! Engaging the transmission or PTO at an elevated engine speed could result in unexpected movement of the equipment. Failure to comply could result in death or serious injury. WARNING Burn Hazard! Keep your hands and other body parts away from hot engine surfaces such as the muffler, exhaust pipe, turbocharger (if equipped) and engine block during operation and shortly after you shut the engine down.
  • Page 236 Never check for a fuel leak with your hands. Always use a Figure 63 piece of wood or cardboard. Consult authorized DOOSAN dealer or DOOSAN after sales service if you have any questions or require more information. Failure to comply could result in death or serious injury.
  • Page 237 WARNING Shock Hazard! Turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the electrical system. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors. Always keep the connectors and terminals clean. FG009151 Figure 64 Failure to comply could result in death or serious injury.
  • Page 238 Failure to comply may result in minor or moderate injury. FG009152 Figure 69 CAUTION Only use diesel fuels recommended by DOOSAN for the best engine performance, to prevent engine damage and to comply with EPA / ARB warranty requirements. Only use clean diesel fuel.
  • Page 239 CAUTION Only use the engine coolant specified. Other engine coolants may affect warranty coverage, cause an internal buildup of rust and scale and / or shorten engine life. Prevent dirt and debris from contaminating the engine coolant. Carefully clean radiator surrounding area before you remove the cap.
  • Page 240 If the ambient temperature is below +5°F (-15°C) the engine will be hard to start and the engine oil may not flow easily. Contact your authorized DOOSAN dealer or distributor if the engine will be operated outside of this standard temperature range.
  • Page 241 CAUTION Make sure the engine is installed on a level surface. If a continuously running engine is installed at an angle greater than 30° (in any direction) or if an engine runs for short periods of time (less than three minutes) at an angle greater than 35°...
  • Page 242 Never attempt to adjust the low or high idle speed limit screw. This may impair the safety and performance of the machine and shorten its life. If the idle speed limit screws require adjustment, see your authorized DOOSAN industrial engine dealer or distributor. Engine...
  • Page 243 Consult your authorized DOOSAN dealer or distributor for assistance when checking items marked with a •. CAUTION...

  • Page 244: Introduction

    DOOSAN Replacement Parts DOOSAN recommends that you use genuine eplacement parts when replacement parts are needed. Genuine replacement parts help ensure long engine life. Required EPA / ARB Maintenance - USA Only...

  • Page 245: Periodic Maintenance Schedule

    Consult your authorized DOOSAN dealer or distributor for assistance when checking items marked with a •. Engine...
  • Page 246 Element Complete Overall Visual Check Daily Engine C : Check R : Replace D : Contact your authorized DOOSAN dealer or distributor Note: These procedures are considered normal maintenance and are performed at the owner’s expense. Engine SP001693 Page 66...

  • Page 247: Periodic Maintenance Procedures

    Periodic Maintenance Procedures After Initial 50 Hours of Operation Perform the following maintenance after the initial 50 hours of operation. • Replace Engine Oil and Engine Oil Filter • Check and Adjust Cooling Fan V-Belt Replace Engine Oil and Engine Oil Filter WARNING Burn Hazard! If you must drain the engine oil while it is still hot, stay clear...
  • Page 248 CAUTION Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility. Never dispose of hazardous materials irresponsibly by FG009156 dumping them into a sewer, on the ground, or into ground Figure 73...
  • Page 249 Remove the engine oil filter as follows: Turn the engine oil filter (2, Figure 76) counterclockwise (3, Figure 76) using a filter wrench. Clean the engine oil filter mounting face. Lightly coat the gasket on the new oil filter with engine oil. Install the new engine oil filter manually by turning it clock wise (4, Figure 76) until it contacts the mounting surface.
  • Page 250 Check and Adjust Cooling Fan V-Belt The V-belt will slip if it does not have the proper tension. This will prevent the alternator from generating sufficient power. Also, the engine will overheat due to the engine coolant pump pulley slipping. Check and adjust the V-belt tension (deflection) as follows: Press the V-belt down with your thumb with a force of approximately 22 ft•lb (98 N•m;...
  • Page 251 Failure to comply will result in death or serious injury. DANGER For maximum engine life, DOOSAN recommends that when shutting the engine down, you allow the engine to idle, without load, for five minutes. This will allow the engine...
  • Page 252 Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow. Stop the engine and allow it to cool. Close the fuel cock of the fuel filter / water separator. Remove the fuel filter with a filter wrench, turning it to the left (1, Figure 83).
  • Page 253 Every 50 Hours of Operation After you complete the initial 50 hour maintenance procedures, perform the following procedures every 50 hours thereafter. • Drain Fuel Filter / Water Separator • Check Battery Drain Fuel Filter / Water Separator DANGER Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions.
  • Page 254 Drain the fuel filter / water separator whenever there are contaminants, such as water, collected in the bottom of the cup. Never wait until the scheduled periodic maintenance if contaminants are discovered. The cup of the separator is made from semi°žtransparent material.
  • Page 255 Check Battery WARNING Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. Battery acid could cause blindness if splashed into the eyes.
  • Page 256 Inspection of Battery Electrolyte Level This machine has two maintenance free battery. It never requires the addition to water. When the charge indicator becomes transparent, it means low electrolyte state because of the leakage or charging system error. Determine the cause of problem and replace the battery immediately.
  • Page 257 Clean Air Cleaner Element Note that a typical air cleaner is shown in Figure 89 and Figure 91 for illustrative purposes only. The engine performance is adversely affected when the air cleaner element is clogged with dust. Be sure to clean the air filter element periodically.
  • Page 258 Every 250 Hours of Operation Perform the following maintenance every 250 hours of operation. • Drain Fuel Tank • Replace Engine Oil • Check and Clean Radiator Fins • Check and Adjust Cooling Fan V-Belt Drain Fuel Tank DANGER Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions.
  • Page 259 That a typical fuel tank is illustrated. Position an approved container under the diesel fuel tank (1, Figure 94) to collect the contaminates. Remove the fuel cap (3, Figure 94). Remove the drain plug (2, Figure 94) of the fuel tank to drain the contaminates (water, dirt, etc.) from the bottom of the tank.
  • Page 260 Check and Clean Radiator Fins CAUTION FLYING OBJECT HAZARD! Always wear eye protection when servicing the engine and when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Failure to comply may result in minor or moderate injury. FG009152 Figure 96 Dirt and dust adhering to the radiator fins reduce the cooling...
  • Page 261 CAUTION FLYING OBJECT HAZARD! Always wear eye protection when servicing the engine and when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Failure to comply may result in minor or moderate injury. FG009152 Figure 99 Blow air (3, Figure 98) through the element from the inside...
  • Page 262 Every 500 Hours of Operation Perform the following maintenance every 500 hours of operation. • Replace Air Cleaner Element • Replace Fuel Filter • Clean Fuel Filter / Water Separator • Replace Engine Oil Filter Replace Air Cleaner Element CAUTION The maximum air intake restriction, in terms of differential pressure measurement, must not exceed 0.90 psi (6.23 kPa;...
  • Page 263 DANGER For maximum engine life, DOOSAN recommends that when shutting the engine down, you allow the engine to idle, without load, for five minutes. This will allow the engine components that operate at high temperatures, such as the exhaust system, to cool slightly before the engine itself is shut down.
  • Page 264 Clean Fuel Filter / Water Separator DANGER Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain conditions. Never use diesel fuel as a cleaning agent. Failure to comply will result in death or serious injury. HDO1015I Figure 103 DANGER Fire And Explosion Hazard! Diesel fuel is flammable and explosive under certain...
  • Page 265 Periodically clean the fuel filter / water separator element and inside cup. Position an approved container under the cup (1, Figure 106) of the fuel filter / water separator to collect the contaminants. Close (2, Figure 106) the fuel cock (3, Figure 106). Loosen the drain cock (4, Figure 106) and drain the contaminants.
  • Page 266 Every 1000 Hours of Operation Perform the following maintenance every 1000 hours of operation. • Adjust Intake / Exhaust Valve Clearance Adjust Intake / Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the valves. Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and engine damage.
  • Page 267 Never check for a fuel leak with your hands. Always use a Figure 107 piece of wood or cardboard. Consult authorized DOOSAN dealer or DOOSAN after sales service if have any questions or required more information. Failure to comply could result in death or serious injury.
  • Page 268 Inspect Crankcase Breather System Proper operation of the crankcase breather system is required to maintain the emission requirements of the engine. The EPA / ARB requires that the crankcase breather system is inspected every 1500 hours. There are three different crankcase breather systems used on the TNV engines.
  • Page 269 Every 2000 Hours of operation Perform the following maintenance every 2000 hours of operation. • Drain, Flush and Refill Cooling System With New Coolant • Check and Replace Fuel Hoses and Engine Coolant Hoses • Lap the Intake and Exhaust Valves Drain, Flush and Refill Cooling System with New Coolant DANGER Scald Hazard!
  • Page 270 CAUTION Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility. Never dispose of hazardous materials irresponsibly by FG009156 dumping them into a sewer, on the ground, or into ground Figure 112...
  • Page 271 • On models equipped with an oil cooler, remove the coolant hose (1, Figure 115) at the oil cooler. Figure 115 After draining the engine coolant, flush the radiator and engine block to remove any rust, scale and contaminants. Then reinstall and tighten the drain plug or close the drain cock in the radiator.

  • Page 272: Engine

    ENGINE Before You Begin Servicing WARNING To preventpossible eye injury, always wear SAFETY GLASSES while servicing the engine. FG009152 Figure 117 WARNING ENTANGLEMENT HAZARD! Stop the engine before you begin to service it. Never leave the key in the key switch when you are servicing the engine.
  • Page 273 CAUTION Flying Object Hazard! Always wear eye protection when servicing the engine and when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Failure to comply may result in minor or moderate injury. FG009152 Figure 120 CAUTION...
  • Page 274 CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced. CAUTION Any part determined to not meet the service standard or limit before the next service, as determined from the state of current rate of wear, should be replaced even though the part currently meets the service standard limit.

  • Page 275: Introduction

    Introduction This section of the Service Manual describes servicing of the engine. Cylinder Head Specifications Adjustment Specifications Valve Bridge Clearance Valve Clearance (4-Valve Head Only) 0.006 - 0.010 in. (0.15 - 0.25 mm) Cylinder Head Reference Inspection Item Standard Limit Page 0.0020 in.
  • Page 276 Push Rod Inspection Item Standard Limit Reference Page Less than 0.0012 in. See “Push Rod Bend” on Push Rod Bend - All Models 0.0012 in. (0.03 mm) (0.03 mm) page -113 Valve Spring Inspection Item Standard Limit Reference Page 1.5630 in. 1.5433 in.

  • Page 277: Camshaft And Timing Gear Train Specifications

    Camshaft and Timing Gear Train Specifications Camshaft Inspection Item Standard Limit Reference Page 0.0020 - 0.0079 in. 0.0118 in. See “Removal of End Play (0.05 - 0.20 mm) (0.030 mm) Camshaft” on page -134 0 - 0.0008 in. 0.0020 in. Bend (1/2 the dial gauge reading) See “Inspection of (0 - 0.02 mm)

  • Page 278: Crankshaft And Piston Specifications

    Crankshaft and Piston Specifications Crankshaft NOTE: Check appropriate parts catalog for various sizes of replacement main bearing inserts. Reference Inspection Item Standard Limit Page 0.0008 in. Bend (1/2 the dial gauge reading) (0.02 mm) 2.2816 - 2.2820 in. 2.2796 in. Journal Outside Diameter (57.952 - 57.962 mm) (57.902 mm)
  • Page 279 Piston Ring Inspection Item Standard Limit Reference Page 0.0803 - 0.0811 in. Ring Groove Width (2.040 - 2.060 mm) 0.0764 - 0.0772 in. 0.0756 in. Ring Width (1.940 - 1.960 mm) (1.920 mm) Top Ring 0.0031 - 0.0047 in. Side Clearance (0.080 - 0.120 mm) 0.0098 - 0.0177 in.

  • Page 280: Cylinder Block Specifications

    Tappet Inspection Item Standard Limit Reference Page Tappet Bore (Block) Inside 0.4724 -0.4731 in. 0.4739 in. Diameter (12.000 - 12.018 mm) (12.038 mm) See “Inspection of 0.4715 - 0.4720 in. 0.4707 in. Tappet Stem Outside Diameter Tappets” on (11.975 - 11.990 mm) (11.955 mm) page -144 0.004 - 0.0017 in.

  • Page 281: Special Torque Chart

    Special Torque Chart Torque for Bolts and Nuts Thread Diameter Lubricating Oil Application Component Torque and Pitch (Thread Portion and Seat Surface) 76 - 83 ft•lb (103.1 - 112.9 Cylinder Head Bolt M11 x 1.25 mm Applied N•m; 8.7 - 9.3 kgf•m) 40 - 43 ft•lb Connecting Rod Bolt M10 x 1.0 mm...

  • Page 282: Special Service Tools

    Special Service Tools Illustration Tool name Applicable model and tool size Model Valve Guide Tool (For Removing Valve 0.787 in. 2.953 in. 0.256 in. 0.394 in. 4TNV98 Guide) (20 mm) (75 mm) (6.5 mm) (10 mm) FG010215 *Locally manufactured Model Valve Guide Tool (For Installing Valve 0.276 in.
  • Page 283 Illustration Tool name Applicable model and tool size Filter Wrench (For Removal / Installation Available Locally of Engine Oil Filter) Model Camshaft Bushing Tool (For Extracting 0.709 in. 2.756 in. 1.968 in. 2.087 in. 4TNV98 Camshaft Bushing) (18 mm) (70 mm) (50 mm) (553 mm) FG010228 *Locally manufactured Model...

  • Page 284: Measuring Instruments

    Illustration Tool name Applicable model and tool size Crankshaft Pulley Locally Manufactured Installing Tool 0.2 A M14x1.5 0.03 A FG008874 Measuring Instruments Illustration Tool name Applicable model and tool size Dial Locally Measure shaft bend and end play Indicator Available Measurements of narrow or deep Test Locally...
  • Page 285 Illustration Tool name Applicable model and tool size Cylinder Locally For measuring the inside diameters of Bore Gauge Available cylinder liners, bearing bores, etc. Locally For measuring outside diameters, Calipers Available depth, thickness and width Depth Locally For measuring of valve recession Micrometer Available Locally...

  • Page 286: 4-Valve Cylinder Head

    4-valve Cylinder Head 4-Valve Cylinder Head Components Figure 121 Engine SP001693 Page 106...
  • Page 287 Reference Reference Description Description Number Number Crankcase Breather Cover Intake Valve Diaphragm Spring Exhaust Valve Diaphragm Cup Cylinder Head Gasket Crankcase Breather Diaphragm Fuel Injector Nozzle Protector Oil Fill Cap Fuel Injector Nozzle Seat Valve Cover Nut Valve Spring Valve Cover Nut O-Ring Valve Bridge Guide Valve Cover Gasket Spring Retainer...
  • Page 288 Disassembly of 4-Valve Cylinder Head Prepare a clean, flat working surface on a workbench large enough to accommodate the cylinder head assembly. Discard all gaskets, O-rings and seals. Use new gaskets, O-rings and seals on reassembly of the cylinder head. Drain the coolant from the engine into a suitable container.
  • Page 289 10. Remove the engine coolant pump. See “Disassembly of Engine Coolant Pump” on page -207 Removal of Valve Cover NOTE: The high pressure fuel injection lines and valve cover grommets must be removed prior to removing the valve cover. See “Removal of Fuel Injectors” on page -194 Remove the high-pressure fuel lines.
  • Page 290 Removal of Rocker Arm Assembly Remove the fuel injectors from the cylinder head. See “Removal of Fuel Injectors” on page -194 Remove the bolts (1, Figure 126) that retain the rocker arm shaft supports to the cylinder head. Remove the rocker arm and shaft assembly from the cylinder head.
  • Page 291 Remove the cylinder head bolts (1, Figure 129) Lift the cylinder head away from the cylinder block. Discard the cylinder head gasket (2, Figure 129). Place the cylinder head on the work bench to prevent damage to the combustion surface. Figure 129 Removal of Intake and Exhaust Valves Place the cylinder head on the work bench with the...
  • Page 292 Removal of Valve Guides Note: Removal of the valve guides should be postponed until inspection measurement procedures have been performed. See “Inspection of Valve Guides” on page -114 Using a drift pin and hammer, drive the valve guides (1, Figure 132) out of the cylinder head. Figure 132 Cleaning of Cylinder Head Components WARNING...
  • Page 293 Inspection of Push Rods Push Rod Bend Place the push rods on a flat inspection block or layout bed. Roll the push rods until a gap can be observed between a portion of the push rod and the surface of the block or layout bed.
  • Page 294 Inspection of Valve Guides Valve Guide Inside Diameter Visually inspect the valve guides for distortions, scoring or other damage. NOTE: Measure the valve guides while they are installed in cylinder head. Use a telescoping gauge and micrometer to measure the inside diameter at each end of the valve guide.
  • Page 295 Valve Stem Bend Place the valve stem on a flat inspection block or layout bed. Roll the valve until a gap can be observed between a portion of the valve stem and the surface of the block or bed. Use a feeler gauge to measure the gap (Figure 140).
  • Page 296 Valve Face and Valve Seat Always check the clearance between the valve and valve guide before grinding or lapping the valve seats. See “Intake / Exhaust Valve and Guide” on page -95 for the service limit. If the clearance exceeds the limit, replace the valve and/or valve guide to bring the clearance within the limit.
  • Page 297 Squareness Use a flat surface and a square to check each spring for squareness (Figure 145). See “Valve Spring” on page -96 for the service limit. Figure 145 Free Length Use a caliper to measure the length of the spring (Figure 146). See “Valve Spring”...
  • Page 298 Reassembly of Valve Guides The valve guides are installed into the cylinder head with an extremely tight press fit. Before installing the valve guides, place the valve guides in a freezer for at least twenty minutes This will cause the valve guides to contract, making it easier to install the valve guides into place.
  • Page 299 Oil the lip of the valve stem seal (2, Figure 150). Using the valve stem seal installation tool (1, Figure 150), install a new valve stem seal on each of the valve guides (3, Figure 150). FG008894 Figure 150 Measure the distance (1, Figure 151) from the cylinder head to the valve stem seal to ensure proper clearance (2, Figure 151) between the guide and seal.
  • Page 300 Reassembly of Cylinder Head Carefully clean both the combustion surface of the cylinder head and the top surface of the cylinder block. Then place a new cylinder head gasket (2, Figure 153) on the cylinder block. Position the cylinder head on the on the cylinder head gasket.
  • Page 301 IMPORTANT The wave washers (2, Figure 156) must be installed with the bow facing the rocker arms (1, Figure 156). Figure 156 IMPORTANT Ensure the lubrication holes (1, Figure 157) in the rocker arm shaft are oriented correctly with respect to the rocker arms (2, Figure 157).
  • Page 302 Reassembly of the Valve Cover Lightly grease a new valve cover gasket (6, Figure 159). Place the gasket in the groove of the valve cover (3, Figure 159). Place the valve cover on the cylinder head. Be sure new O-rings (5, Figure 159) are installed on the valve cover nuts.

  • Page 303: Measuring And Adjusting Valve Clearance

    Measuring and Adjusting Valve Clearance Measure and adjust while the engine is cold. NOTE: The No. 1 piston position is on the flywheel end of the engine, opposite the radiator. The firing order is 1-3-2 for 3-cylinder engines and 1-3-4-2 for 4-cylinder engines.
  • Page 304 4-Valve Cylinder Heads The 4-valve cylinder head operates two valves with a single rocker arm by employing a valve bridge (1, Figure 160) between the two valves (2, Figure 160). Clearance (4, Figure 160) between the valve bridge and valves must be set before adjusting the clearance (5, Figure 160) between the rocker arm (3, Figure 160) and valve bridge.
  • Page 305 To assure the valve bridge contacts the rear valve, apply light, downward (4, Figure 162) finger pressure on the valve bridge (3, Figure 162), and loosen the valve bridge adjusting screw (1, Figure 162), until there is visible clearance (2, Figure 164) between the adjusting screw and the front valve.
  • Page 306 To adjust the actual valve clearance between the rocker arm and the valve bridge, insert a feeler gauge (1, Figure 165) correct thickness (See “Adjustment Specifications” on page -95) between the rocker arm (2, Figure 165) and valve bridge (3, Figure 165). Record the results and use this value as an indication of wear.
  • Page 307 Engine SP001693 Page 127...

  • Page 308: Crankshaft And Camshaft Components

    Crankshaft and Camshaft Components Figure 167 Engine SP001693 Page 128...
  • Page 309 Reference Reference Description Description Number Number Cylinder Block Crankshaft Gear Key Camshaft Bushing Crankshaft Gear Gear Case (4TNV98-E) Crankshaft Pulley Dowel (2 used) Main Bearing Inserts O-Ring Main Bearing Cap Front Plate (4TNV98-E) Oil Pan Gear Case Cover (4TNV98-E) Thrust Bearings Front Crankshaft Seal Flywheel Gear Case Cover (4TNV98-E)
  • Page 310 Disassembly of Engine Prepare a clean, flat working surface on a workbench large enough to accommodate the engine components. Discard all used gaskets, O-rings and seals. Use new gaskets, O-rings and seals on reassembly of engine. CAUTION Identify all parts and their location using an appropriate method.
  • Page 311 Disassembly of Camshaft and Timing Components Discard all gaskets, O-rings and seals. Use new gaskets, O- rings and seals on reassembly of the camshaft and timing components. Removal of Timing Gear Case Cover Remove the bolt and washer retaining the crankshaft pulley.
  • Page 312 Measuring Idler Gear-to-Crankshaft Gear Backlash Install a dial indicator as shown in Figure 170. Rotate the idler gear back and forth to check the idler gear-to-crankshaft gear backlash. The total indicator reading is the backlash. Record the measurement. Figure 170 Measuring Idler Gear-to-Camshaft Gear Backlash Drive a small wooden wedge between the crankshaft gear and idler gear to prevent the idler gear from rotating.
  • Page 313 Removal of Oil Pan Invert the engine (oil pan up) on the engine stand. Remove the oil pan (1, Figure 173). Figure 173 Remove the oil pickup tube (1, Figure 174) and O-ring (2, Figure 174). Figure 174 Engine SP001693 Page 133...
  • Page 314 Removal of Camshaft Before removing the camshaft, check the camshaft end play. • Method A: Install a dial indicator (1, Figure 175) on the cylinder block. Move the camshaft (2, Figure 175) back and forth to measure the end play. Record the measurement.
  • Page 315 Removal of Gear Case or Front Plate Note: The camshaft must be removed before the gear case / front plate can be removed. See “Inspection of Camshaft” on page -146 Remove the oil pump. NOTE: It is not necessary to remove the fuel injection pump from the gear case / front plate to remove the gear case / front plate.
  • Page 316 Disassembly of Crankshaft and Piston Components Remonal of Pistons CAUTION Keep the piston pin parts, piston assemblies, and connecting rod assemblies together to be returned to the same position during the reassembly process. Label the parts using an appropriate method. IMPORTANT Engines with high operating hours may have a ridge near the top of the cylinders that will catch the piston rings and...
  • Page 317 Place a piece of PLASTIGAGE (1, Figure 180) along the full width of the bearing insert. IMPORTANT rotate crankshaft when using PLASTIGAGE. A false reading may result. Reinstall bearing cap and tighten to specification. See “Torque for Bolts and Nuts” on page -101 Figure 180 Remove bearing cap.
  • Page 318 Remove the bearing inserts (2, Figure 182). Remove the compression rings (3, Figure 182) from the piston using a piston ring expander. Remove the oil ring (4, Figure 182) from the piston using a piston ring expander. Remove the circlips (5, Figure 182) from the wrist pin. Remove the wrist pin (6, Figure 182) and connecting rod (8, Figure 182) from the piston (9, Figure 182).
  • Page 319 • Method B: Use a feeler gauge to measure the clearance (3, Figure 185) between the thrust bearing (1, Figure 185) and crankshaft (2, Figure 185). Record the measurement. See “Thrust Bearing” on page -98 for the service limit. FG008937 Figure 185 Remove the main bearing caps (3, Figure 186).
  • Page 320 If necessary, remove the crankshaft gear (1, Figure 189), parallel pin (2, Figure 189) and key (3, Figure 189). If using a gear puller, be careful not to damage the threads in the end of the crankshaft. Figure 189 Inspection of Crankshaft and Camshaft Components WARNING Fume / Burn Hazard! Always read and follow safety related precautions found on...
  • Page 321 Remove the rear oil seal (3, Figure 192) from the seal housing (2, Figure 192). Apply a continuous bead of ThreeBond Liquid Gasket to the outside diameter of a new oil seal (2, Figure 192), and install in the housing. Apply lithium grease to the lip of the seal.
  • Page 322 Inspection of Cylinder Block Ensure that oil passages are clear and unobstructed. Check for discoloration or evidence of cracks. If a fracture is suspected, use the color check method or the Magnaflux method to determine if the cylinder block is fractured.
  • Page 323 Measure the diameter of the wrist pin bore on both sides of the piston (Figure 195). See “Piston” on page -98 for specifications. Record the measurements. FG008944 Figure 195 Measure the outside diameter of the wrist pin in three places and at 90° (Figure 196). See “Piston” on page -98 for specifications.
  • Page 324 Inspection of Connecting Rod Measure the wrist pin bushing bore using a bore gauge (1, Figure 199). Replace the bushing if not within specifications. If the bushing has been removed, measure the inside diameter of the connecting rod small end (2, Figure 199).
  • Page 325 Inspection of Crankshaft Place the crankshaft end journals (4, Figure 202) on V- blocks. Place a dial indicator (3, Figure 202) on a center main bearing surface. Rotate crankshaft observe runout. “Crankshaft” on page -98 for specifications. Use the color check method or Magnaflux to inspect the crankshaft for cracks.
  • Page 326 Inspection of Camshaft Use V-blocks and a dial indicator to check camshaft bend (Figure 204). Place the indicator on the center bearing journal. Rotate the camshaft and observe the runout. See “Camshaft” on page -97 for specifications. Figure 204 Measure the height of each lobe (1, Figure 205) See “Camshaft”...
  • Page 327 Inspection of Idler Gear and Shaft Measure the outside diameter (1, Figure 207) of the idler gear shaft (2, Figure 207). See “Idler Gear Shaft and Bushing” on page -97 for specifications. Measure the inside diameter (3, Figure 207) of the idler gear bushing (4, Figure 207) See “Idler Gear Shaft and Bushing”...
  • Page 328 NOTE: When honing a cylinder, with either a ridged hone or a ball hone (1, Figure 209), move the rotating hone up and down in the cylinder bore to accomplish a 30° to 40° crosshatch pattern (Figure 209). This will provide the ideal surface for the proper seating of new piston rings.
  • Page 329 Reassembly of Pistons Select the parts needed to reassemble the piston and connecting rod for one cylinder. If removed, install a new wrist pin bushing (7, Figure 210) using a press and the appropriate service tool. Be sure to align the oil holes. Reinstall one circlip (5, Figure 210) into the piston.
  • Page 330 Piston Assembly - 4TNV98-E When correctly assembled, the piston identification mark (2, Figure 212) stamped into the top of the piston will be on the same side of the connecting rod as the match marks (4, Figure 212) stamped into the connecting rod and connecting rod cap.
  • Page 331 Reinstall the oil ring expander (4, Figure 214). Reinstall the oil ring (3, Figure 214) with the end gap at 180° from the expander end gap. Reinstall the second compression ring (2, Figure 214). This ring is identified by its dark color and tapered face profile.
  • Page 332 Installation of Crankshaft If removed, reinstall the keys and timing gear on he crankshaft. Reinstall new bearing inserts (1, Figure 216) and thrust bearing (2, Figure 216) in the cylinder block and main bearing caps. Apply a liberal coat of clean engine oil to the bearings and crankshaft journals.
  • Page 333 Rotate the crankshaft so the crankpin for the piston being installed is near bottom dead center. IMPORTANT Ensure the piston ring gaps are located correctly (Figure 218) Reference Description Number Figure 218 Top Compression Ring End Gap Second Compression Ring End Gap Oil Ring End Gap Using a piston ring compressor, compress the piston rings.
  • Page 334 Reinstall the bearing inserts (1, Figure 220) in the connecting rod and cap. Apply a liberal coat of clean engine oil to the bearing inserts and crankshaft journal. Apply a light coat of clean engine oil to the rod cap bolts. Reinstall the connecting rod cap (2, Figure 220).
  • Page 335 so they will not interfere with the installation of the camshaft. Lubricate the camshaft (2, Figure 222) with clean engine oil or assembly lube. Slowly insert the camshaft through the front of the engine. Reinstall and tighten the cap screws (3, Figure 222). If removed, reinstall the fuel injection pump.
  • Page 336 Installation of Timing Gears Set the No. 1 piston to top dead center. Rotate the camshaft until the mark (C, Figure 223) is approximately at the 9 o’clock position. Reference Description Number Fuel Injection Pump Drive Gear Camshaft Drive Gear Auxiliary Drive Gear (Optional) Crankshaft Drive Gear Direction of Rotation...
  • Page 337 Reinstall the crankshaft pulley. IMPORTANT 4TNV98-E: Use the crankshaft pulley installation tool (3, Figure 226) when reinstalling the pulley (1, Figure 226). The tool will guide the pulley hub and protect the front seal (2, Figure 226) from damage.v Reinstall the washer and bolt. Tighten the bolt to the specified torque.
  • Page 338 Installation of Oil Pan Reinstall the oil pickup tube (1, Figure 227) using a new O- ring (2, Figure 227). Figure 227 Apply a continuous bead of ThreeBond Liquid Gasket to the mounting surface of the oil pan (Figure 228, 1). Be sure to circle each bolt hole.
  • Page 339 Final Reassembly of Engine Reinstall the starter motor. Reinstall the cylinder head. See “Reassembly of Cylinder Head” on page -120 for the 2-valve cylinder head or See “Reassembly of Cylinder Head” on page -120 for the 4- valve cylinder head. Reinstall the engine in the machine.

  • Page 340: Egr System

    EGR System EGR System Figure 229 Reference Reference Description Description Number Number Exhaust manifold Intake manifold EGR pipe Cooling water hose, EGR valve inlet EGR valve Cooling water hose, EGR valve outlet Engine SP001693 Page 160...
  • Page 341 DANGER Scald Hazard! Never Remove the radiator cap if the engine is hot. Steam and hot engine coolant will spurt out and seriously burn you. Allow the engine to cool down before you attempt to remove the radiator cap. Tighten the radiator cap securely after you check the HAOA060L radiator.
  • Page 342 WARNING Fume / Burn Hazard! Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. Failure to comply could result in death or serious injury. FG009153 Figure 233 CAUTION FLYING OBJECT HAZARD! Always wear eye protection when servicing the engine and when using compressed air or high-pressure water.
  • Page 343 CAUTION The EGR system uses steel gaskets at the joints between its components/parts. These steel gaskets are specific to the respective joints. When you remove the system's components/parts and reinstall them, replace the steel gaskets between them with new correct ones. Drain the engine cooling water.
  • Page 344 Standard value Terminal Resistance (Ω) 1 - 2 15 ± 2 2 - 3 4 - 5 at 20°C 5 - 6 NOTE: The higher the temperature, the higher the coil resistance. Therefore, wait for the EGR valve to return to normal state before measuring the resistances.
  • Page 345 Cleaning the EGR Valves WARNING Fume / Burn Hazard! Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. Failure to comply could result in death or serious injury. FG009153 Figure 238 CAUTION...
  • Page 346 Precautions for Installation The valve and stopper must be installed in their specific orientations. As shown in the figure above, install the valve and stopper so that they are located on the left-hand side of the lead valve. Install the valve by tightening the machine screw while ensuring that it is evenly positioned inside the case window.

  • Page 347: Fuel System

    FUEL SYSTEM Before You Begin Servicing WARNING Entanglement Hazard! Stop the engine before you begin to service it. Never leave the key in the key switch when you are servicing the engine. Someone may accidentally start the engine and not realize you are servicing it. This could result in a serious injury.
  • Page 348 WARNING Fume / Burn Hazard! Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. Failure to comply could result in death or serious injury. FG009153 Figure 242 CAUTION FLYING OBJECT HAZARD! Always wear eye protection when servicing the engine and when using compressed air or high-pressure water.
  • Page 349 CAUTION Never use a steel wire brush to clean fuel injectors. Damage to the nozzle and other components is likely to result. CAUTION Allow the engine to warm-up for at least five minutes and the idle speed of the engine to return to normal before engaging the transmission or any PTOs.

  • Page 350: Introduction

    TNV DI model engines. Fuel Injection Pump NOTE: If the MP fuel injection pump itself requires servicing, it must be taken to an authorized DOOSAN dealer or DOOSAN after soles service. CAUTION Never remove or attempt to remove the tamper-proof...
  • Page 351 Stop Solenoid The MP fuel injection pumps are equipped with a stop solenoid that controls the fuel flow inside the fuel injection pump. With the starter switch in the OFF position, no current flows to the stop solenoid and the solenoid plunger is extended holding the fuel injection pump fuel rack in the "closed"...
  • Page 352 Cold Start Device The TNV model engines are equipped with a cold start device (CSD). The cold start device is located in the upper section of the fuel injection pump and is connected to the engine°Øs cooling system. • The cold start device improves engine starting at lower temperatures.
  • Page 353 Electronically Controlled Governor Electronically controlled engines 4TNV98-E are quipped with an electronically controlled governor called "Eco Governor". Combined with the rack actuator (3, Figure 246), engine speed sensor (5, Figure 246), and other parts, the electronically controlled governor communicates with the engine controller (E-ECU), whereby the engine speed and fuel injection rate are controlled.

  • Page 354: Fuel System Specifications

    Fuel System Specifications Special Torque Chart Lubricating Oil Application Component Tightening Torque (Thread Portion and Seat Surface) 29 ft•lb Fuel Injector Retainer Bolt Not Applied (39.2 N•m; 4 kgf•m) 83 - 91 ft•lb Fuel Pump Drive Gear Nut Not Applied (113 - 123 N•m;...

  • Page 355: Measuring Instruments

    DOOSAN Part No. indicator in plunger Adapter Clamp 23000-013000 adapter. These special service tools may also be available as an "MP Fuel Injection Pump Special Tool Set". Contact your authorized DOOSAN dealer or distributor for details. Engine SP001693 Page 175...

  • Page 356: Fuel System Diagram

    Fuel System Diagram Figure 247 Engine SP001693 Page 176...
  • Page 357 Reference Reference Description Description Number Number Diesel Fuel Tank Tappet Fuel Filter / Water Separator High Pressure Gallery Electric Fuel Pump Overflow Orifice Fuel Filter Accumulator Air Bleed Orifice Timer Piston Fuel Supply Line Mono-Plunger Low Pressure Gallery Distributor Shaft Pressure Control Valve Fuel Return Line Trochoid Pump...

  • Page 358: Fuel System Components

    Fuel System Components 4-Valve Cylinder Head Figure 248 Engine SP001693 Page 178...
  • Page 359 Reference Reference Description Description Number Number High-Pressure Fuel Injection Lines Coolant Lines for Cold Start Device* Fuel Return Line Fuel Injection Pump Insulator Return Line-to-Cylinder Head Bolt Diesel Fuel Injection Pump Fuel Injector Rear Fuel Injection Pump Support Injection Line Grommet Fuel Filter / Water Separator Front Plate or Timing Gear Case Electric Fuel Supply Pump...

  • Page 360: Fuel Injection Pump

    Fuel Injection Pump Removal of Fuel Injection Pump Loosen the cooling fan V-belt. Remove the engine coolant fan guard (if equipped), engine coolant fan (2, Figure 250), spacer (3, Figure 250) if equipped, V-pulley (4, Figure 250) and cooling fan V- belt (1, Figure 250).
  • Page 361 11. Remove the throttle cable from the fuel injection pump. 12. Separate the stop solenoid wiring connector (2, Figure 252). 13. Remove the rear fuel injection pump bracket(s) (1, Figure 252) from the fuel injection pump. NOTE: Configuration of the fuel injection pump rear brackets may vary depending upon engine model.
  • Page 362 • The idler gear is visible. Make a reference mark (1, Figure 255) across both the fuel injection pump drive gear and the idler gear. CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub.
  • Page 363 Do not rotate the crankshaft with the injection pump removed. Figure 260 25. If the fuel injection pump requires servicing, it must be sent to an authorized DOOSAN after sales service for repair and calibration, or replaced with a new fuel injection pump. CAUTION...
  • Page 364 WARNING Replacing the fuel injection pump involves rewriting the fuel injection data in the E-ECU. Be sure to contact your local DOOSAN dealer before replacing the fuel injection pump. Failure to rewrite the fuel injection data before replacing the fuel injection pump will void the engine warranty.
  • Page 365 Figure 263 If installing the fuel injection pump on an engine with the front gear case cover removed, the fuel injection pump drive gear can be aligned with the idler gear by aligning the stamped marks (A, B, C) on the fuel injection pump drive gear, idler gear, and crankshaft drive gear.
  • Page 366 If reinstalling the original fuel injection pump: • Align the reference marks (1, Figure 266) previously made on both the fuel injection pump mounting flange and gear case or front plate. • Tighten the fuel injection pump retaining nuts to specification.
  • Page 367 Adjusting the fuel injection timing to compensate for the difference in pump timing index numbers: Calculation Example Timing Index Number Original injection pump= Replacement injection pump= Difference= +0.5 • If the difference between the timing index numbers is a positive number, thefuel injection pump mounting position must be advanced (2, Figure 269) (rotated away from the engine) as compared to the "standard mark"...
  • Page 368 Reconnect the throttle linkage and the stop solenoid connector (2, Figure 272). Reconnect the lube oil line (1, Figure 272) and clamp (2, Figure 272). Apply ThreeBond Liquid Gasket or equivalent sealant to the sealing surface of the pump cover. Install the pump cover and tighten the cover bolts.

  • Page 369: Checking And Adjusting Fuel Injection Timing

    Checking and Adjusting Fuel Injection Timing Determining the Fuel Injection Timing Specification Locate and record the fuel injection pump timing index number (1, Figure 276) stamped into the boss on the engine side of the fuel injection pump housing (1, Figure 275).
  • Page 370 Checking Fuel Injection Timing NOTE: Some fuel may drain from the fuel injection pump during this process. Make provisions to contain any such spillage. Turn off the fuel valve in the fuel supply hose and the fuel return hose. Clamp shut the fuel injection pump fuel return hose leading to fuel filter (1, Figure 278).
  • Page 371 Using a wrench on the crankshaft pulley bolt, rotate the crankshaft in a clockwise direction while looking through the flywheel inspection port (1, Figure 281). Rotate the crankshaft until the injection timing marks on the flywheel are visible. Figure 281 Typical flywheel markings are as shown in (1, Figure 282).
  • Page 372 • EXAMPLE: If the distance between the two "longer" marks is approximately 2.0 cm and the distance from the TDC mark is approximately 4.0 cm, the answer is approximately 2. This indicates there is 10° (2 x 5°) between the TDC mark and the first "longer" mark on the timing grid.
  • Page 373 Adjusting Fuel Injection Timing If the timing marks did not align when performing the Checking Fuel Injection Timing on page 7-27, the following steps must be performed to properly time the engine. Leave the dial indicator installed in the fuel injection pump.

  • Page 374: Fuel Injectors

    Fuel Injectors Removal of Fuel Injectors 4-Valve Cylinder Head Close any fuel valves in the fuel supply line. Remove the valve cover. Remove the injector return line (1, Figure 287). Be careful not to bend the line. Remove the fuel injector mounting clamp bolts (2, Figure 287).
  • Page 375 CAUTION Never inject fuel toward you. Since the fuel is injected at high pressure from the nozzle, it may penetrate the skin, resulting in injury. Never inject fuel toward a fire source. Atomized fuel is highly flammable and may cause a fire or burn skin. CAUTION FLYING OBJECT HAZARD! Always wear eye protection when servicing the engine...
  • Page 376 FG009005 Figure 291 Engine SP001693 Page 196...
  • Page 377 Disassembly and Inspection of Fuel Injectors CAUTION Never use a steel wire brush to clean fuel injectors. Damage to the nozzle and other components is likely to result. Clean carbon from used injectors using clean diesel fuel. Hardened deposits or varnish can be cleaned using a brass wire brush.
  • Page 378 Adjusting Fuel Injector Pressure fuel injectors open when pressure reaches predetermined pressure threshold. They close when the pressure is reduced below that threshold. The pressure threshold can be adjusted by adding or removing shims (3, Figure 294). Reference Description Number Fuel Return Passage Injector ID Location Injector Body...
  • Page 379 Reassembly of Fuel Injectors Secure the injector in a soft-jawed vise with the nozzle end Reinstall the shims, nozzle spring, nozzle spring seat, valve stop spacer, nozzle valve, and nozzle body. Reinstall the nozzle case nut. Tighten it to specification. See “Special Torque Chart”...

  • Page 380: Cooling System

    COOLING SYSTEM Before You Begin Servicing DANGER Scald Hazard! Never Remove the radiator cap if the engine is hot. Steam and hot engine coolant will spurt out and seriously burn you. Allow the engine to cool down before you attempt to remove the radiator cap.
  • Page 381 WARNING Fume / Burn Hazard! Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. Failure to comply could result in death or serious injury. FG009153 Figure 300 WARNING Burn Hazard! If you must drain the engine oil while it is still hot, stay clear of the hot engine oil to avoid being burned.
  • Page 382 CAUTION Only use the engine coolant specified. Other engine coolants may affect warranty coverage, cause an internal buildup of rust and scale and / or shorten engine life. Prevent dirt and debris from contaminating the engine coolant. Carefully clean radiator surrounding area before you remove the cap.

  • Page 383: Introduction

    Introduction This section of the Service Manual describes the procedures necessary to service the standard engine coolant pump. This engine coolant pump is representative of the coolant pumps used on other TNV model engines. For specific part detail, see the parts catalog for the engine you are working on. Cooling System Diagram Figure 304 Reference...

  • Page 384: Engine Coolant Pump Components

    Engine Coolant Pump Components Figure 305 Reference Reference Description Description Number Number Thermostat Cover Gasket Thermostat Cover Gasket Engine Coolant Pump Gasket Thermostat V-Belt Thermostat O-Ring Engine Coolant Pump V-Pulley Special O-Ring Spacer Engine Coolant Pump Engine Coolant Fan Temperature Switch Engine SP001693 Page 204...

  • Page 385: Engine Coolant System Check

    Engine Coolant System Check Check the engine coolant system for leakage. With the radiator properly filled, install a cooling system tester (1, Figure 306). Apply 10.8 -14.8 psi (75 -105 kPa; 0.75 -1.05 kgf/cm ) to the cooling system. If the pressure reading drops, the engine coolant system is leaking.
  • Page 386 Drain the coolant from the engine block. • On models equipped with an oil cooler, remove the coolant hose (1, Figure 308) at the oil cooler. • On models not equipped with an oil cooler, remove the coolant drain plug (1, Figure 309) from the engine block.
  • Page 387 Disassembly of Engine Coolant Pump Remove the thermostat cover (1, Figure 312) Discard the gasket. Remove the thermostat (2, Figure 312). Discard the O- ring. Remove the temperature switch (3, Figure 312) and gasket (4, Figure 312). Discard the gasket. Figure 312 Cleaning and Inspection Temperature Switch...
  • Page 388 Thermostat Check for proper operation of the thermostat. Place the thermostat (1, Figure 315) and an accurate thermometer (2, Figure 315) in warm water. Slowly increase the temperature of the water using an external heat source. The thermostat is operating properly if it starts to open at the temperature value stamped on the flange of the thermostat, and fully opens as the temperature of the water is increased.
  • Page 389 CAUTION Use a new special O-ring between the engine coolant pump and the joint. Be sure to use the special O-ring each engine model. Although O-ring dimensions are the same as a commercially available O-ring, the material is different. Reinstall the engine coolant pump bolts. Tighten the bolts. Inspect and reinstall the coolant hoses and the temperature switch lead wire.

  • Page 390: Lubrication System

    LUBRICATION SYSTEM Before You Begin Servicing WARNING Entanglement Hazard! Stop the engine before you begin to service it. Never leave the key in the key switch when you are servicing the engine. Someone may accidentally start the engine and not realize you are servicing it. This could result in a serious injury.
  • Page 391 CAUTION FLYING OBJECT HAZARD! Always wear eye protection when servicing the engine and when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Failure to comply may result in minor or moderate injury. FG009152 Figure 323 CAUTION...

  • Page 392: Introduction

    Introduction This section of the Service Manual describes the procedures necessary to service the 4TNV98-E Trochoid oil pumps. See “Replace Engine Oil and Engine Oil Filter” on page -79 for engine oil and engine oil filter replacement procedures. Oil Pump Service Information Engine Oil Pressure At Rated Engine RPM 1500 - 1800...

  • Page 393: Lubrication System Diagram

    Lubrication System Diagram Oil Filter Turbocharger* Bypass Valve Oil Cooler* Fuel Injection Pump Oil Pressure Switch Cylinder Body-Main Gallery Pressure Regulator Valve Camshaft Crank Idle Gear Oil Pump Bearing Journal Shaft Piston Cooling Rocker Arm Crank Pin Oil Suction Pipe Nozzles* Bearing Strainer...

  • Page 394: Checking Engine Oil Pressure

    Checking Engine Oil Pressure Perform an engine oil pressure check if there is any indication of low oil pressure such as the oil pressure indicator is on or the oil pressure gauge indicates low oil pressure. See “Oil Pump Service Information” on page -212 Disconnect the wire lead from the oil pressure switch or sending unit (1, Figure 325).
  • Page 395 Remove the crankshaft pulley and the gear case cover. See Removal of Timing Gear Case Cover on page 6-73. Figure 327 Remove the oil pump assembly bolts. Remove the oil pump assembly (1, Figure 328) from the gear case housing (2, Figure 328).
  • Page 396 Outer Rotor to Inner Rotor Tip Clearance Determine the outer rotor to inner rotor tip clearance. Insert a feeler gauge between the top of an inner rotor tooth (1, Figure 330) and the top of an outer rotor tooth (2, Figure 330) and measure the clearance.
  • Page 397 Reassembly of Oil Pump Lubricate the outer rotor and pump bore in the gear case with clean engine oil. Reinstall the outer rotor in the gear case housing. The punch mark (1, Figure 333) on the end of the outer rotor must face away from the gear case housing (2, Figure 333).

  • Page 398: Starter Motor

    STARTER MOTOR Before You Begin Servicing WARNING Entanglement Hazard! Stop the engine before you begin to service it. Never leave the key in the key switch when you are servicing the engine. Someone may accidentally start the engine and not realize you are servicing it. This could result in a serious injury.
  • Page 399 CAUTION FLYING OBJECT HAZARD! Always wear eye protection when servicing the engine and when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Failure to comply may result in minor or moderate injury. FG009152 Figure 339 CAUTION...

  • Page 400: Introduction

    Introduction This section of the Service Manual covers the servicing of the starter motor. Standard equipment on TNV model engine is used in this section to show the service procedures for a representative start motor and it may be different from acfural equipment.

  • Page 401: Starter Motor Troubleshooting

    Starter Motor Troubleshooting FG009097 Figure 340 Engine SP001693 Page 221...

  • Page 402: Starter Motor Components

    Starter Motor Components Figure 341 Reference Reference Description Description Number Number Pinion Shaft Magnetic Switch Assembly (Solenoid) M4 Bolts (3 used) Cover Bearing Retainer M6 Bolts (2 used) Pinion Clutch Assembly Armature Assembly Return Spring Field Coil Assembly Pinion Stop Positive (+) Brushes Retaining Ring Negative (-) Brushes...
  • Page 403 Starter Motor WARNING Shock Hazard! Turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the electrical system. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors. Always keep the FG009151 connectors and terminals clean. Figure 342 Failure to comply could result in death or serious injury.
  • Page 404 Remove the two M4 bolts (1, Figure 345) securing the rear cover (2, Figure 345) to the brush holder assembly (3, Figure 345). Remove the two M5 through bolts (4, Figure 345). Separate the rear cover (2, Figure 345), field coil assembly (5, Figure 345) with the armature assembly (6, Figure 345) from the gear housing (7, Figure 345).
  • Page 405 Disassemble the dust cover (3, Figure 349) and shift the lever (4, Figure 349) from the gear housing. Figure 349 Remove the three M4 bolts (1, Figure 350) securing the bearing retainer assembly (2, Figure 350) to the gear housing. Remove the bearing retainer assembly from the gear housing.
  • Page 406 Cleaning and Inspection Armature Commutator Surface Inspection if the commutator is rough, polish the surface with a #500 to #600 emery cloth (Figure 353). Figure 353 Measure Commutator Outside diameter Measure Commutator Outside diameter (Figure 354). Replace the armature if the measurement is less than the limit. See “Starter Motor Specifications”...
  • Page 407 Armatire Coil Continuity Test Check for continuity between the commutator segments using a multimeter (Figure 356). The multimeter should indicate continuity. If the multimeter does not indicate continuity, replace the armature. Figure 356 Armature Coil Insulation Test Check for continuity between a commutator segment and the shaft or armature using a multimeter (Figure 357).
  • Page 408 Field Coil Field Coil Continuity Test Check for continuity between the field coil terminals using a multimeter (Figure 359). The multimeter should indicate continuity. If the multimeter does not indicate continuity, replace the field coil assembly. Figure 359 Field Coil Insulation Test Check for continuity between the field coil terminal and the yoke using a multimeter (Figure 360).
  • Page 409 Magnetic Switch If the starter motor becomes wet, replace the magnetic switch even if the magnetic switch assembly function is normal. Shunt Coil Continuity Test Check for continuity between the "S" terminal and the switch body using a multimeter (Figure 362). The multimeter should indicate continuity.
  • Page 410 Pinion Clutch Assembly Pinion Clutch Assembly Inspection Manually rotate the pinion clutch assembly in the drive direction (Figure 365). It should rotate freely in the drive direction and is locked by turning it in the opposite direction. Replace the pinion clutch assembly if the results are different.
  • Page 411 Reassembly of Starter Motor Apply appropriate starter bendix grease (obtain locally) to the pinion shaft. Reassemble the pinion shaft (5, Figure 368), pinion clutch assembly (1, Figure 368), return spring (4, Figure 368) and pinion stop (3, Figure 368). Reinstall the retaining ring (2, Figure 368) in the groove in the pinion shaft.
  • Page 412 Position the brush springs in brush holders (Figure 372). Reinstall the brushes in the brush holders. Reversing the brushes will cause the starter motor to turn backwards. Carefully install the brush holder assembly to the armature assembly. 10. Reinstall the field coil assembly with the armature assembly to the gear housing.
  • Page 413 Check Pinion Projection Length Connect the positive (+) lead from a battery to the "S" terminal. Connect the negative (-) lead to the "M" terminal. Lightly pull the pinion away from the gear housing. Turn the switch ON and measure the pinion moving distance L in the thrust direction (Figure 374).
  • Page 414 No-Load Test Test the characteristics of the starter motor by performing a no- load test. CAUTION The starter motor can be damaged if operated continuously longer than 10 seconds while performing the no-load test. Secure the starting motor in a vise or other suitable fixture. Connect an ammeter (1, Figure 376) in series between the battery positive (+) terminal (2, Figure 376) and the main positive (+) terminal (3, Figure 376) on the starter motor.
  • Page 415 ALTERNATOR Before You Begin Servicing WARNING ENTANGLEMENT HAZARD! Stop the engine before you begin to service it. NEVER leave the key in the key switch when you are servicing the engine. Someone may accidentally start the engine and not realize you are servicing it. This could result in a serious injury.
  • Page 416 WARNING FUME / BURN HAZARD! Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. Failure to comply could result in death or serious injury. FG009153 Figure 381 CAUTION FLYING OBJECT HAZARD! ALWAYS wear eye protection when servicing the engine and when using compressed air or high-pressure water.
  • Page 417 Machine safety signs and labels are additional reminders for safe operating and maintenance techniques. See your authorized DOOSAN dealer or distributor for additional training. CAUTION Do not short-circuit the charging system between alternator terminals IG and L.
  • Page 418 Agricultural or other chemicals, especially those with a high sulfur content, can adhere to the IC regulator. This will corrode the conductor and result in battery over-charging (boiling) and charging malfunctions. Consult DOOSAN dealer before using the equipment in such an environment or the warranty is voided.
  • Page 419 Introduction This section of the Service Manual describes the servicing of the dynamos and alternators. Standard equipment on TNV model engine is used in this section to show the service procedures for a representative dynamos and alternators and it may be different from acfural equipment.
  • Page 420 Alternator Troubleshooting FG009100 Figure 384 Engine SP001693 Page 240...
  • Page 421 Engine SP001693 Page 241...
  • Page 422 Alternator Components Part No. 129423-77200 alternator is used in this section to show the service procedures for the representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on. Figure 385 Engine SP001693 Page 242...
  • Page 423 Reference Reference Description Description Number Number Pulley Insulation Bushing Collar Spring (2 used) Front Frame Housing Brush Holder Stator Assembly Rear Frame Housing Stud (2 used) Bolt (2 used) Front Frame Housing Bearing Holder Bearing Cover IC Regulator Assembly Bearing Cover Bolt (4 used) Bolt (2 used) Rotor Assembly Bolt...
  • Page 424 Alternator Wiring Diagram FG009102 Figure 386 Reference Reference Description Description Number Number Key Switch Battery Charge Lamp (3.4 Watts Max.) Alternator Assembly Load IC Regulator Assembly CAUTION Do not short-circuit the charging system between alternator terminals IG and L. Damage to the alternator will result. CAUTION Do not connect a load between alternator terminals L and E.
  • Page 425 Alternator Standard Output STANDAED CHAEACTERISTICS 13.5V CONTANT AMBIENT TEMP:25 C Cold ALTERNATOR SPEED (X10 min ) FG008440 Figure 387 Engine SP001693 Page 245...
  • Page 426 Alternator WARNING SHOCK HAZARD! Turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the electrical system. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors. ALWAYS keep the FG009151 connectors and terminals clean. Figure 388 Failure to comply could result in death or serious injury.
  • Page 427 Disassembly of Alternator Remove the nut (1, Figure 390) from the shaft of the rotor assembly. Remove the pulley (2, Figure 390). Figure 390 Remove the three bolts (1, Figure 391) retaining the rear cover (2, Figure 391) to the rear frame assembly. Remove the brush holder (3, Figure 391).
  • Page 428 Using a press, remove the rotor assembly (1, Figure 394) from the front frame housing (2, Figure 394) and rear frame housing (1, Figure 394). Figure 394 Remove the stator assembly (1, Figure 395) from the front frame housing. 10. If it is necessary to replace the bearing (2, Figure 395) in the front frame housing, remove the four bolts (3, Figure 395) securing the plate (4, Figure 395) to the front frame housing.
  • Page 429 Reassembly of Alternator If removed, reinstall the two trust washers (3, Figure 397) and bearing cover (2, Figure 397) in the rear frame housing. Lubricate the outside diameter of a new bearing (1, Figure 397). Press the bearing into the rear frame housing.
  • Page 430 Reinstall the insulation bushing (4, Figure 401) and nut (3, Figure 401). Reassemble the regulator assembly (1, Figure 401) to the holder (2, Figure 401). Figure 401 Reinstall the brush holder (3, Figure 402), springs (4, Figure 402) and brushes (5, Figure 402). Reattach the regulator assembly and holder to the rear frame housing.
  • Page 431 Installation of Alternator Position the alternator on the gear case. Loosely reinstall the nut (2, Figure 404) on the gear case stud and the V- belt adjuster bolt (1, Figure 404). Reconnect the electrical wires to the alternator. Tighten the nuts to 15 - 20 in.-lb (1.7 -2.3 N•m ; 17-23 kgf•m). Reinstall the V-belt.
  • Page 432 Dynamo Component Location Standard dynamo is used in this section to show the service procedures for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working on. Figure 405 Reference Reference Description Description Number Number Rear Cover...
  • Page 433 Dynamo Wiring Diagram FG009112 Figure 406 Reference Reference Description Description Number Number Dynamo Charge Lamp (3.4 Watts Max.) IC Regulator Assembly Battery Key Switch Load Operation of Dynamo The dynamo consists of a series of permanent magnets that rotate around a stationary stator coil. The magnets are attached to the flywheel which is rotated via the engine cooling fan drive belt.
  • Page 434 Dynamo Standard Output STANDARD CHARACTERISTICS (12V) 7x10 ALTERNATOR SPEED (min ) FG009113 Figure 407 Engine SP001693 Page 254...
  • Page 435 Testing of Dynamo Use a circuit tester or multimeter to perform the following tests. Testing Stator Coil Continuity Disconnect the dynamo output wire connector. Connect one meter lead to each of the stator wire terminals and read the meter. NOTE: The meter reading should indicate continuity.
  • Page 436 Dynamo Removal of Dynamo Disconnect the output wire connector from the dynamo. Loosen the V-belt. CAUTION PINCH HAZARD! Carefully rotate the alternator toward the cylinder block while loosening the V-belt. Failure to comply may result in minor or moderate injury. Remove the V-belt adjuster from the dynamo bolt (1, Figure 408).
  • Page 437 Remove the through bolt (1, Figure 410), pulley half (2, Figure 410), flywheel (3, Figure 410), flat washer (4, Figure 410), bearings (5, Figure 410), and spacer (6, Figure 410). Figure 410 Remove the screws (1, Figure 411) and the stator assembly (2, Figure 411).
  • Page 438 Reinstall the flat washer (4, Figure 414), lock washer (3, Figure 414), and nut (2, Figure 414). Tighten the nut to the specified torque. Reinstall the rear cap (1, Figure 414). Figure 414 Installation of Dynamo Position the dynamo on the gear case. Loosely reinstall the nut (2, Figure 415) on the gear case stud and the V- belt adjuster bolt (1, Figure 415).
  • Page 439 ELECTRIC WIRING Electric Wiring Precautions Failure to follow these precautions may result in the failure of an electrical component and the loss of warranty coverage on that item as well as related items. Make sure that all users read and understand these precautions.
  • Page 440 CAUTION Reversing the battery cable connections at the battery or on the engine will destroy the SCR diode in the current limiter. This will cause the charging system to malfunction and may cause damage to the electrical harnesses. Electrical Wire Resistance Metric Nominal Ohms / Foot Resistance...
  • Page 441 Battery Cable Resistance Maximum Total Battery Cable Length (Positive Cable + Negative Cable + a*) 12V Starter Motor Output Less Than 2.68 HP (2 kW) Greater Than 2.68 HP (2 kW) 4.75 12.6 15.3 0 (1/0) 19.5 11.6 00 (2/0) 22.8 13.7 000 (3/0)
  • Page 442 Electrical Wire Sizes - Voltage Drop Length of conductor from source of current to device and back to source (in feet) Total current circuit amps Wire Size (AWG) Volts Volts Engine SP001693 Page 262...
  • Page 443 Conversion of Awg to European Standards Conductor Cross-sectional Area Conductor Size Conductor Diameter (AWG) (mm) 0.455 0.163 0.511 0.205 0.573 0.259 0.644 0.325 0.723 0.412 0.812 0.519 0.992 0.653 1.024 0.823 1.15 1.04 1.29 1.31 1.45 1.65 1.63 2.08 1.83 2.63 2.05 3.31...
  • Page 444 TROUBLESHOOTING Special Service Tools For measuring compression pressure Gauge Set Compression Gauge Adapter for direct injection 4-valve cylinder head for 4TNV98 - Z FG009120 Engine SP001693 Page 264...
  • Page 445 Troubleshooting by Measuring Compression Pressure Compression pressure drop is one of the major causes of increasing blow-by gas (engine oil contamination or increased engine oil consumption as a resultant phenomenon) or starting failure. The compression pressure is affected by the following factors: Degree of clearance between the piston and cylinder Degree of clearance at the intake / exhaust valve seat...
  • Page 446 After performing the compression check remove the compression gauge and compression gauge adapter from the cylinder. Install the fuel valves. See See “Installation of the Fuel Injectors” on page -199 See “Inspection of Valve Guides” on page -114 Then install the valve covers and injection high pressure lines.
  • Page 447 Measured Value and Troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. Item Cause Corrective Action Clogged element Clean the element. Air Cleaner Element Broken element Replace the element. Defect at element seal portion Valve Clearance Excessive or no clearance...
  • Page 448 Quick Reference Table for Troubleshooting The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service life. Engine SP001693 Page 268...
  • Page 449 Failure Diagnosis Table Engine stall Engine Noise and Cooling Intake Starting failure Speed control error Lubricating oil Exhaust gas Fuel Electrical parts Symptoms and conditions of failure after start up output low vibration water Starter does Starter Work Smoke Work Smoke No load not rotates...
  • Page 450 Engine stall Engine Noise and Cooling Intake Starting failure Speed control error Lubricating oil Exhaust gas Fuel Electrical parts Symptoms and conditions of failure after start up output low vibration water Starter does Starter Work Smoke Work Smoke No load not rotates rotates load...
  • Page 451 Engine stall Engine Noise and Cooling Intake Starting failure Speed control error Lubricating oil Exhaust gas Fuel Electrical parts Symptoms and conditions of failure after start up output low vibration water Starter does Starter Work Smoke Work Smoke No load not rotates rotates load...
  • Page 452 Engine stall Engine Noise and Cooling Intake Starting failure Speed control error Lubricating oil Exhaust gas Fuel Electrical parts Symptoms and conditions of failure after start up output low vibration water Starter does Starter Work Smoke Work Smoke No load not rotates rotates load...
  • Page 453 Engine stall Engine Noise and Cooling Intake Starting failure Speed control error Lubricating oil Exhaust gas Fuel Electrical parts Symptoms and conditions of failure after start up output low vibration water Starter does Starter Work Smoke Work Smoke No load not rotates rotates load...
  • Page 454 Electrical wiring NOTE: The following wiring diagram is “representative” of a common installation using a TNV engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine manufacturer for specific information. YAZAKI NO. YAZAKI NO.
  • Page 455 SP001627 DRIVE COUPLING (MAIN PUMP)SP001627 Drive Coupling (Main Pump) Edition 1 Drive Coupling (Main Pump) SP001627 Page 1...
  • Page 456 MEMO Drive Coupling (Main Pump) SP001627 Page 2...
  • Page 457 Table of Contents Drive Coupling (Main Pump) Safety Precautions..........5 Applicable Models ..........5 Drive Coupling............6 Installation of Drive Coupling ....... 7 Installation Procedure ............. 7 Drive Coupling (Main Pump) SP001627 Page 3...
  • Page 458 MEMO Drive Coupling (Main Pump) SP001627 Page 4...

  • Page 459: Drive Coupling (Main Pump)

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Drive Coupling (Main Pump) SP001627 Page 5...

  • Page 460: Drive Coupling

    DRIVE COUPLING Figure 1, show typical drive coupling installations. ENGINE FG013229 Figure 1 Reference Reference Description Description Number Number Coupling Bolt Washer Pump Bolt Washer Pump Cover Bolt Washer Drive Coupling (Main Pump) SP001627 Page 6...

  • Page 461: Installation Of Drive Coupling

    INSTALLATION OF DRIVE COUPLING Always follow the following installation procedure when installing the drive coupling in the main pump. NOTE: Noncompliance with the procedure may cause noise or shortening of life of the drive coupling or the main pump. Installation Procedure Assemble the coupling (1, Figure 1) in the engine flywheel with spring washers (2, Figure 1) and bolts (3, Figure 1).
  • Page 462 Drive Coupling (Main Pump) SP001627 Page 8...
  • Page 463 Hydraulics...
  • Page 465 SP000028 ACCUMULATOR SP000028 Accumulator Edition 1 Accumulator SP000028 Page 1...
  • Page 466 MEMO Accumulator SP000028 Page 2...
  • Page 467 Table of Contents Accumulator Safety Precautions..........5 Applicable Models ..........5 General Description ..........6 Specifications..............8 Accumulator SP000028 Page 3...
  • Page 468 MEMO Accumulator SP000028 Page 4...

  • Page 469: Safety Precautions

    The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX27Z 5001 and Up DX35Z 5001 and Up DX55 50001 and Up DX60R 50001 and Up DX80R 50001 and Up DX180LC 5001 and Up DX225LC 5001 and Up DX225NLC 5001 and Up...

  • Page 470: General Description

    GENERAL DESCRIPTION The accumulator is a gas-charged storage device designed to hold a reserved quantity of hydraulic fluid under pressure. Accumulators are used in hydraulic circuits in as much the same way as condensers (or capacitors) are used to collect, store and maintain electrical charge in a circuit.
  • Page 471 button on the bottom of the diaphragm eventually seals off the lower oil passage. Just after the needle on the gauge reaches its highest point (when there is 0 bar (0 psi) resistance from hydraulic system pressure) pressure on the gauge will drop sharply to zero, as the accumulator is completely emptied of oil and the diaphragm button closes.

  • Page 472: Specifications

    (19.53 in 320 cc 10 kg/cm DX55 S/N 50001 and Up Pilot (142 psi) (19.53 in 320 cc 10 kg/cm DX60R S/N 50001 and Up Pilot (142 psi) (19.53 in 320 cc 10 kg/cm DX80R S/N 50001 and Up Pilot (142 psi) (19.53 in...
  • Page 473 SP001628 CENTER JOINT (SWIVEL)SP001628 Center Joint (Swivel) Edition 1 Center Joint (Swivel) SP001628 Page 1...
  • Page 474 MEMO Center Joint (Swivel) SP001628 Page 2...
  • Page 475 Table of Contents Center Joint (Swivel) Safety Precautions..........5 Applicable Models ..........5 General Description ..........6 Disassembly Diagram ............. 6 Disassembly ............7 Reassembly ............9 Center Joint Assembly ........11 Center Joint (Swivel) SP001628 Page 3...
  • Page 476 MEMO Center Joint (Swivel) SP001628 Page 4...

  • Page 477: Center Joint (Swivel)

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up Center Joint (Swivel) SP001628...

  • Page 478: General Description

    GENERAL DESCRIPTION The center joint (swivel) is designde to allow hydraulic oil from the upper structure to flow to components in the lower structure. It is capable of allowing continuous 360° rotation of the upper structure in relationship to the lower structure. Disassembly Diagram FG013233 Figure 1...

  • Page 479: Disassembly

    DISASSEMBLY CAUTION It is recommended to use a hoist or a similar device for it is heavy. CAUTION Remove active oil and wash it out before starting disassembly. CAUTION It should be sisassembled after it’s active oil is cool enough after it is removed form the system for it’s active oil is very hot.
  • Page 480 Separate the Hub into 8 sliper seals, 1 O-ring (1BP80), and 1 Dust seal (LBH80). CAUTION Care should be taken not to damage the inside of the because likely damaged when disassembling slipper seal. disassembled more easily with a driver whose tip is bent as shown in the figure below.

  • Page 481: Reassembly

    REASSEMBLY CAUTION Apply active oil to every funcational (moving) part before assembly to reduce any assembly friction as much as possible. FG013239 Figure 6 Wrap the teflon tape around the PT plug about 6 ~ 10 times. Assemble the PT plug into the washed shaft. PT 1/4: 6 mm wrench PT 3/8: 8 mm wrench Engagement torque:...
  • Page 482 CAUTION Applying active oil to the surface of the shaft enables the assembly without any damage to the sliper seal. Fix the position of the shaft and press the hub carefully into shaft with both being parallel each other. Use a plastic (or urbber) hammer to tap the hub until it is inserted completely.
  • Page 483 CENTER JOINT ASSEMBLY FG013245 Figure 9 Center Joint (Swivel) SP001628 Page 11...
  • Page 484 Center Joint (Swivel) SP001628 Page 12...
  • Page 485 SP001629 CYLINDERS SP001629 Cylinders Edition 1 Cylinders SP001629 Page 1...
  • Page 486 MEMO Cylinders SP001629 Page 2...
  • Page 487 Table of Contents Cylinders Safety Precautions..........5 Applicable Models ..........5 General Description ..........6 Theory of Operation ............6 Parts List................8 Special Tools and Materials ....... 16 Piston Nut ..............16 Piston Jig............... 17 Steel Bushing Jig ............18 Dust Wiper Jig...............
  • Page 488 MEMO Cylinders SP001629 Page 4...

  • Page 489: Safety Precautions

    Use lifting and hoisting equipment capable of safely handling the load. Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Cylinders SP001629 Page 5...

  • Page 490: General Description

    GENERAL DESCRIPTION wo essentially similar types of hydraulic cylinders are used on the excavator. The cylinder that is used to operate the excavator boom or bucket is equipped with a rod stopper, which acts as a cushion only when the cylinder rod is fully retracted (and the bucket is pulled close to the arm).
  • Page 491 Because the volume of oil needed to lengthen the cylinder rod (Q1) is greater than the volume of oil required to retract the cylinder rod, it takes more time to decrease cylinder stroke length than it does to lengthen it. = S x π(B = S x π(B >...

  • Page 492: Parts List

    Parts List The following parts list is a partial listing only; for full and complete parts list information, refer to the Hydraulic Equipment Component Parts List Cross section in Figure 4 shows an arm cylinder. Cross section in Figure 5 shows a boom cylinder. The bucket and boom cylinders are identical and differ only in the attached pipes.
  • Page 493 Reference Reference Description Description Number Number Tube Assembly Ring, Back Up Bush O-ring Rod Assembly Ring, Cushion Bush Piston Rod Cover Ring, Glyd DD-bush Ring, Wear Ring, Retaining Ring, Dust Seal, Buffer O-ring U-packing Ring, Back Up Wiper, Dust Nut, Piston Ring, Retaining Screw, Set O-ring...
  • Page 494 Arm Cylinder FG011072 Figure 5 Cylinders SP001629 Page 10...
  • Page 495 Reference Reference Description Description Number Number Tube Assembly Piston Bush Ring, Glyd Rod Assembly Ring, Wear Bush Ring, Dust Rod Cover O-ring DD-bush Ring, Back Up Ring, Retaining Nut, Piston Seal, Buffer Screw, Set U-packing Plunger, Cushion Wiper, Dust Ring, Stop Ring, Retaining Valve, Check O-ring...
  • Page 496 Bucket Cylinder FG011073 Figure 6 Cylinders SP001629 Page 12...
  • Page 497 Reference Reference Description Description Number Number Tube Assembly Ring, Back Up Bush O-ring Rod Assembly Piston Bush Ring, Glyd Rod Cover Ring, Wear DD-bush Ring, Dust Ring, Retaining O-ring Seal, Buffer Ring, Back Up U-packing Nut, Piston Wiper, Dust Screw, Set Ring, Retaining Nipple, Grease O-ring...
  • Page 498 Boom Swing Cylinder FG013247 Figure 7 Cylinders SP001629 Page 14...
  • Page 499 Reference Reference Description Description Number Number Tube Assembly Ring, Back Up Bush O-ring Rod Assembly Washer Bush Piston Rod Cover Ring, Glyd DU-bush Ring, Dust U-packing Ring, Wear Ring, Back Up O-ring Wiper, Dust Nut, Piston Ring, Retaining Screw, Set O-ring Nipple, Grease Cylinders...

  • Page 500: Special Tools And Materials

    Rockwell Harden from 22 - 27 Oil Quench Model Cylinder øA (mm) øB (mm) C (mm) D (mm) 106.0 66.0 11.0 BOOM 112.0 72.0 11.0 DX60R BUCKET 106.0 66.0 11.0 SWING 109.0 69.0 11.0 114.0 74.0 11.0 BOOM 119.0 79.0 11.0...

  • Page 501: Piston Jig

    Rockwell Harden from 22 - 27 Oil Quench Model Cylinder øA (mm) øB (mm) C (mm) D (mm) 65.0 12.0 22.0 52.0 BOOM 80.0 12.0 25.0 55.0 DX60R BUCKET 65.0 12.0 22.0 52.0 SWING 80.0 12.0 25.0 55.0 75.0 12.0 27.0 60.0 BOOM 75.0 12.0...

  • Page 502: Steel Bushing Jig

    Place: Finally work to used DNMG Tip <Nose R0.4> Model Cylinder øA (mm) øB (mm) E (mm) F (mm) 50.0 58.0 20.0 BOOM 50.0 58.0 20.0 DX60R BUCKET 50.0 58.0 20.0 SWING 50.0 20.0 DOZER 65.0 70.0 30.0 65.0 78.0 20.0...

  • Page 503: Dust Wiper Jig

    Undefined Chamfer C/R = 0.5 Max. Place: Finally work to used DNMG Tip <Nose R0.4> Model Cylinder øA (mm) øB (mm) C (mm) D (mm) 53.0 69.0 BOOM 58.0 74.0 DX60R BUCKET 55.0 62.0 DOZER 80.0 74.0 63.0 79.0 BOOM 68.0 84.0 DX80R BUCKET 53.0...

  • Page 504: Slipper Seal Jig

    Slipper Seal Jig (B+40) ARS4770L Figure 12 Model Cylinder øA (mm) øB (mm) 79.5 11.5 BOOM 104.5 21.5 DX60R BUCKET 79.5 SWING 109.5 20.5 DOZER 109.5 99.6 BOOM 114.6 DX80R BUCKET 84.5 28.5 SWING 109.5 DOZER 99.6 19.5 Cylinders SP001629...

  • Page 505: Slipper Seal Straightening Jig

    Slipper Seal Straightening Jig ∅ ARS4780L Figure 13 Model Cylinder øA (mm) 85.7 BOOM 105.7 DX60R BUCKET 80.7 DOZER 110.7 100.7 BOOM 115.7 DX80R BUCKET 85.7 SWING 110.7 DOZER 100.7 Cylinders SP001629 Page 21...

  • Page 506: Disassembly

    DISASSEMBLY CAUTION Vent air from the hydraulic system before disconnecting cylinder piping connections. Use the lever on the reservoir, while the engine is running. Discharge the hydraulic accumulator and vent residual tank pressure after the engine is shut off. Pour clean replacement fluid back into the system if excessive fluid is lost.
  • Page 507 Tap two bolts into cover of cylinder head, 180° apart. Tighten them in a staggered, even sequence, to back off piston rod end cover from edge of cylinder wall. Look for adequate clearance between cover and end of cylinder wall before using a plastic or other soft-faced hammer for final disassembly.
  • Page 508 Figure 21 Fabricate or purchase a piston nut removal wrench. (Dimensions are called off at beginning of this procedure. This tool may also be ordered through your local DOOSAN Parts distributor). Remove nut from end of piston. Figure 22 Cylinders...
  • Page 509 10. Use second piston tool described at beginning of this procedure to separate piston. Detach cushion ring (15), taking care not to damage cushion ring. Figure 23 11. Use a plastic hammer to evenly pull off rod cover (9) from end of piston rod.
  • Page 510 14. Pull off O-ring (20) and backup ring (21) from cylinder head. HAOF38OL Figure 27 15. During disassembly of cylinder head, be careful not to damage buffer seal (5) and U-packing (4). HAOF39OL Figure 28 16. Disassemble retaining ring (3) and dust wiper (2). Separate retaining ring (8) and rod bushing (6).
  • Page 511 17. Force out pin bushing (1) from body of cylinder. Figure 30 Cylinders SP001629 Page 27...

  • Page 512: Assembly

    ASSEMBLY IMPORTANT Replace any part that shows evidence of damage or excessive wear. Replacement of all O-rings and flexible seals is strongly recommended. Before starting the cylinder assembly procedure, all parts should be thoroughly cleaned and dried, and/or prelubricated with clean hydraulic fluid.
  • Page 513 Prelubricate O-rings and seals before assembly (Figure 33). Figure 33 Before starting to rebuild piston assembly, heat slipper seal for 5 minutes in an oil bath warmed to 150°-180°C (302°-356°F). Use special slipper seal jig (third item in list of specialized tools at the beginning of this procedure) to attach seal.
  • Page 514 Use specially fabricate or factory sourced tool to tighten piston nut (22). Figure 37 Assemble wear ring (18), slide ring (17) and set screw (23) to piston assembly. Reference Number Description Set Screw Figure 38 Immobilize body of cylinder before assembly. Figure 39 10.
  • Page 515 SP001630 SWING MOTOR SP001630 Swing Motor Edition 1 Swing Motor SP001630 Page 1...
  • Page 516 MEMO Swing Motor SP001630 Page 2...
  • Page 517 Table of Contents Swing Motor Safety Precautions..........5 Applicable Models ..........5 Indication of Type ..........6 Specifications ............7 Construction and Principles of Working ....8 Construction ..............8 Principles of Working ............ 10 Precaution in Use ..........14 Inspection..............
  • Page 518 MEMO Swing Motor SP001630 Page 4...

  • Page 519: Swing Motor

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Swing Motor SP001630 Page 5...

  • Page 520: Indication Of Type

    INDICATION OF TYPE — — — Design Code Pinion Shaft Type Max. Theoretical Output Torque Reduction Gear Type Mechanical Brake Yes or No B: Brake Built-in Valve Cover Code Displacement 32: 31.5 cc/rev 29: 28.98 cc/rev Motor Type Swing Motor SP001630 Page 6...

  • Page 521: Specifications

    SPECIFICATIONS MODEL TSM32 (S)CAB-RG250D Displacement 31.5 cc/rev Set Pressure of Relief Valve 220 kgf/cm Theoretical Output Torque (Motor) 10.5 kg•m Rated Flow Rate 38.5 lpm Brake Torque 14.5 kgf•m Brake Release Pressure 10 ~ 20 kgf/cm Theoretical Output Torque 205 kgf•m Gear Ratio 19.464 Weight...

  • Page 522: Construction And Principles Of Working

    CONSTRUCTION AND PRINCIPLES OF WORKING Construction 9,10 32,33,34, 35,36,37 FG013250 Figure 1 Swing Motor SP001630 Page 8...
  • Page 523 Reference Reference Description Description Number Number Casing Spacer Valve Casing Throttle Plate Drive Shaft Spring Roller Bearing RO Plug Ball Bearing RO Plug Shoe Plate Plug Retainer Plate Orifice Piston assembly Snap Ring Piston assembly Socket Bolt Spherical Bush Relief Valve Cylinder Spring Gear Casing Cylinder Block...

  • Page 524: Principles Of Working

    Principles of Working Motor Part High pressure oil from the control valve is routed through valve casing and valve plate to pistons. When the oil enters the cylinder bores through port, it forces the pistons against the fixed inclined swash plate (F1, F2). The force (F2) causes the piston shoes to slide on the swash plate forcing the rotating group to turn, thereby rotating the output shaft.
  • Page 525 Valve Casing Part Anticavitation Check Valve The motor can be rotated faster than supplied oil flow because there is no counter-balancing valve to prevent over speed ; in order to prevent cavitation of the motor, oil compensation insufficient flow is drawn through the anti- cavitation check valve.
  • Page 526 Figure 4 Relief Valve: TSR25A Working Description Swing Motor SP001630 Page 12...
  • Page 527 Brake Part The swing brake is spring applied and hydraulically released. Friction plate (15) are splined to and rotate with cylinder block. separation plates (15) are splined to the motor casing (1). When the swing controller blocks pilot pressure at port (SH), the brake springs (17) force on brake piston (16) squeeze the separation and friction plates together to prevent the upper structure from swinging.

  • Page 528: Precaution In Use

    PRECAUTION IN USE Inspection Prior to installation of a new motor, inspect the following items. Inspect whether or not there is any damage during transit, or if any parts are lost missing. Inspect each tightened part is loosened or not. Check whether or not covers for flange surface and drain port are perfect, and the inside of the motor is dirty with intruded dust.

  • Page 529: Hydraulic Fluids And Range Of Temperature

    Hydraulic Fluids and Range of Temperature Mineral Oil Please use a highly viscosity index working fluid which has additions of anti-foam agent, oxidation inhibitors, corrosion inhibitors, viscosity index improvers, oiliness agent and the oil with a high viscosity. Optimum viscosity and temperature (Figure 7) In order to obtain the highest performance of the motor, oil which has a viscosity in a range of 10 to 200 cst is most suitable.

  • Page 530: Filter

    Except mineral oil Incase if using special fluid (phosphate ester compounds, water-glycol, fluid fatly acid ester compound, etc.), please consult us for instruction prior to use. Filter If fine particles of dirt and metal are mixed with oil, they enter into sliding surfaces and accelerate wear in each part, and in the worst case seizure will be likely to occur.

  • Page 531: Oil Filling

    Oil Filling Fill in the casing with oil using the drain port before the operating. In the motor, there are many kinds of high-speed sliding surface like bearing, piston, shoe, spherical bush, and etc. So If there isn’t enough oil, can make some problem like sticking or breaking in those parts.

  • Page 532: Troubleshooting

    TROUBLESHOOTING General Cautions Here, counter-measures to be taken when troubles have happened while the motor is in operation are described. As for general precaution. Consider a cause of the trouble before repairing Before setting to work, think whether the same thing has happened before or not.

  • Page 533: Condition And Countermeasures Of Troubles

    Condition and Countermeasures of Troubles Motor does not rotation Condition Cause Remedy The pressure of the 1. Setting pressure of relief valve is 1. Reset the pressure to correct value. circuit incorrect. increasing 2. Working defectiveness of relief 1) Revise or exchange of stick face. valve.
  • Page 534 Brake torque is not sufficient. Condition Cause Remedy 1. Disassembly or inspection. When it is Brake torque is not 1. Friction plates are worn. sufficient worn better than standard, replace it. 2. Brake piston is becoming stick. 2. Disassembly or inspection 3.

  • Page 535: Disassembling And Assembling

    DISASSEMBLING AND ASSEMBLING Tightening Torque of Bolts It is shown tightening torque of bolts used in motor. In case of reassembling, tighten accurately each bolt in accordance. Tightening Torque Bolt Size Name Part NO. (kgf•cm) Hexagon bolt 1, 040 ± 160 RO Plug 900 ±...
  • Page 536 Figure 9 Special tool for removing the brake piston Swing Motor SP001630 Page 22...

  • Page 537: Disassembly Of Motor

    Disassembly of Motor Please use the following procedures for the inspection and repair of the motor. Numerals given in parentheses following the parts names indicate the parts number shown by the drawing in the instruction and maintenance manual. Completely remove dirt and dust adhering to the outside. Discharge all hydraulic fluid in the motor casing and the port oil passage.Use a clean, dust-free work area.
  • Page 538 Remove the valve plate (18). Figure 13 Remove the bearing (5) and the pin (22). Figure 14 Remove brake springs (17). Figure 15 Remove the O-ring (26, 27). Figure 16 Swing Motor SP001630 Page 24...
  • Page 539 Remove brake piston (16) from the casing (1) by using the special tool for removing the brake piston. Lift it up straight by using the bolt hole in the brake piston. Figure 17 10. Pull out friction plate (14, 2EA) and separation plate (15, 1EA) from the casing (1).
  • Page 540 13. Remove the spherical bush (11). Figure 21 14. Remove the cylinder spring (12). Figure 22 15. Remove the drive shaft (3). Figure 23 16. Remove the shoe plate (7). Figure 24 Swing Motor SP001630 Page 26...
  • Page 541 17. Remove the bearing (4). Figure 25 18. Remove the relief valve (44). CAUTION Do not disassemble the relief valve assembly because it is a functional component. Figure 26 19. Remove the plug (21), the spring (20) and the plunger (19).

  • Page 542: Assembly Of Motor

    Assembly of Motor Following are caution to be specially borne in mind. Rework damaged parts and before assembling, prepare all parts to be replaced. Clean all parts and dry with compressed air. Coat the sliding parts and bearing with clean hydraulic oil.
  • Page 543 Assemble the relief valve (44). Figure 32 Assemble roller bearing (4) in the casing (1) with a using of tool. Figure 33 Apply grease to the back side of the shoe plate (7) and assembly it. Figure 34 Assemble the drive shaft (3) in the casing (1). Figure 35 Swing Motor SP001630...
  • Page 544 Apply grease to the O-ring (23, 24) and assemble it. Figure 36 Assemble the cylinder spring (12). Figure 37 10. Assemble the spherical bush (11). Figure 38 11. Set the piston assembly (9, 10) on the retainer plate (8) and assembly it in the cylinder block (13). CAUTION Apply an ample amount of hydraulic fluid to the sliding part before assembly.
  • Page 545 12. Assemble the cylinder block (13) and other associated parts. Figure 40 13. Assemble the friction plate (14, 2EA) and separation plate (15, 1EA). Figure 41 14. Assemble the brake piston (16). Figure 42 15. Assemble the brake spring (17). Confirm the springs are fitted to the brake piston completely.
  • Page 546 16. Assemble the O-ring (26, 27). Figure 44 17. Press-fit the ball bearing (5). Assembly the pin (22). Figure 45 18. Assembly the valve plate (18). Be careful to note the direction of the valve plate. Mount the valve plate with its round part toward the opposite side of the flange.
  • Page 547 20. Mount valve casing (2) to casing (1) and tighten hex socket bolts (43) to specification. Figure 48 The assembly is completed. Swing Motor SP001630 Page 33...

  • Page 548: Disassembly Of Reduction Gear

    Disassembly of Reduction Gear Please use the following procedures for the inspection and repair of the reduction gear. Numerals given in parentheses following the parts names indicate the parts number shown by the drawing in the instruction and maintenance manual. Wind the wire rope at reduction gear outside, lift up the reduction gear, and clean the reduction gear with cleaning oil.
  • Page 549 Remove the carrier No.2 sub-assembly (R8). Figure 52 Remove the following parts. Reference Number Description Snap ring Inner ring No.1 Needle bearing Planet gear No.1 Thrust washer No.1 Thrust washer No.2 Figure 53 Secure the carrier No.2 in a vice and loosen the screw (R22) to remove the thrust plate (R20).
  • Page 550 Remove the half collar (R7). Figure 56 10. Remove the pinion shaft (R2). CAUTION When removing the pinion shaft, be careful not to drop it. If it is hard to remove, lightly strike it with a plastic hammer. Figure 57 11.

  • Page 551: Assembly Of Reduction Gear

    Assembly of Reduction Gear Following are caution to be specially borne in mind. Rework damaged parts and before assembling, prepare all parts to be replaced. Clean all parts and dry with compressed air. Coat the sliding parts and bearing with clean hydraulic oil.
  • Page 552 Install the pinion shaft (R2) and other associated parts. CAUTION Prior to assembling the pinion shaft, etc. Apply grease slightly on the lip surface to prevent any scratch when installing. Figure 63 Install the taper roller bearing (R4) with a using of tool. Figure 64 Install the half collar (R7) with a using of tool.
  • Page 553 Install the following parts. Reference Number Description Thrust plate Screw CAUTION Apply loctite to the screw prior to tightening it. Figure 67 Install the carrier No.2 sub-assembly (R8). Figure 68 10. Install the sun gear No.2 (R17). Be sure to check the direction of sun gear when assembling.
  • Page 554 12. Install the carrier No.1 sub-assembly (R9). Turn the carrier slowly by hand to adjust the matching holes when assembling. Figure 71 13. Install the sun gear No.1 (R18). Be sure to check the direction of sun gear when assembling. Figure 72 14.

  • Page 555: Maintenance Standards

    MAINTENANCE STANDARDS Part Replacement Standards for Hydraulic Motor If the various parts of the motor have been worn out beyond the following standard values, please replace them. But this shall apply only to those cases when is no remarkable outside damage.

  • Page 556: Part Replacement Standards For Reduction Gear

    Part Replacement Standards for Reduction Gear Standard Recommended Item Dimension Value for Remedy (mm) Replacement (mm) Replace if pitting or crack Pitting or crack of gear Pitting area rate: 10% is found. Overpin: 28.194 Motor driving shaft external spline 27.594 (Z=15) (ø3.048) Overpin: 19.767...

  • Page 557: Standard For Correcting Sliding Surfaces

    Standard for Correcting Sliding Surfaces If the surface roughness of the sliding surface of a part exceeds the following standards, correct it or replace the part. Item Surface Roughness Roughness Requiring Correction 0.8 - Z (Ra=0.2) Shoe 3 - Z (Ra=0.8) (LAPPING) 0.4 - Z (Ra=0.1) Shoe Plate...
  • Page 558 Swing Motor SP001630 Page 44...
  • Page 559 SP001686 TRAVEL MOTOR SP001686 Travel Motor Edition 1 Travel Motor SP001686 Page 1...
  • Page 560 MEMO Travel Motor SP001686 Page 2...
  • Page 561 Table of Contents Travel Motor Safety Precautions..........6 Applicable Models ..........6 General ..............7 Configuration..............7 Features ................7 Structural Diagram of the Travelling System ....8 Structural Diagram of the Axial Piston Motor ....9 Operating Principle ..........10 When Travelling.............
  • Page 562 General Suggestions When Working ......29 Disassembly Procedure ..........30 Service Preparations .......... 48 Seals................48 Service Standards for Parts Subject to Wear....48 Assembly ............50 Preparation..............50 General Suggestions When Working ......50 Assembly Procedure............. 51 Performance Confirmation Test ......71 Clearance Adjustment Part Dimensions.....

  • Page 563: Travel Motor

    MEMO Travel Motor SP001686 Page 5...

  • Page 564: Safety Precautions

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Travel Motor SP001686 Page 6...

  • Page 565: General

    GENERAL CONFIGURATION The travel motor is a decelerator contained tilting axial piston motor and has 6 built-in functions, which are; tilting axial piston motor, counter adjusting valve, crossover relief valve, 2-speed changeover device, packing brake, and decelerator. The motor converts the energy of the pressurized oil discharged from the pump into mechanical energy and also transfers high-speed torque power to the decelerator.

  • Page 566: Structural Diagram Of The Travelling System

    Structural Diagram of the Travelling System Figure 1 Reference Reference Description Description Number Number Axial Piston Motor Crossover Relief Valve Decelerator 2-speed Travel Changeover Device Counter Adjusting Valve Parking Brake Travel Motor SP001686 Page 8...

  • Page 567: Structural Diagram Of The Axial Piston Motor

    Structural Diagram of the Axial Piston Motor The Cylinder Block contains 9 pistons and the valve plate is connected to the base of the cylinder block. When high-pressure oil (P) flows through port B, pistons push the swash plate with force F = P.A (where A is the surface area of the piston bore) and the pushing force is translated into rotational movement by the Swash Plate and the shaft is rotated.

  • Page 568: Operating Principle

    OPERATING PRINCIPLE When Travelling When the control valve is in the state as shown in figure below, pressurized oil from the hydraulic pump will flow into P1 port of the brake valve. The pressurized oil flowing through P1 port will push to open the check valve contained in the plunger, and then flow though M1 port and attempt to rotate the hydraulic motor.

  • Page 569: When Counterbalance Operates

    When Counterbalance Operates When the rotation speed of the hydraulic motor is excessively high, the quantity of the hydraulic oil being discharged from M2 port is more than the quantity of oil being input through M1 port. The P1 port pressure will decrease and the set spring pressure will overcome the pressure being applied to the end of the plunger.

  • Page 570: When Brake Functions

    When Brake Functions When control valve is in the neutral position, then there will be no hydraulic oil discharged from the hydraulic pump. This will result in equalizing both pressure of ports P1 and P2 and in having the plunger return to the neutral position due to spring force, thus shutting notch on the outer pillar of the plunger.

  • Page 571: Operating Principle Of Parking Brake

    Operating Principle of Parking Brake Parking brake consists of friction board, piston, and spring. Cylinder block and friction board are interconnected through a spool line. Friction board produces friction force by means of spring. Pressurized oil that entered the motor will open the release port of the parking brake and push the spring that presses the friction board, thus releasing the brake.

  • Page 572: Speed Limiting Function

    2 Speed Limiting Function At Low Speed As shown on the following figure, tilting plate is braced at three sides (a, b and c), and is machined so as to enable rotation by means of 2 scale balls. In case of low speed, spools are driven by spring to stand at the position as shown on the figure, and pistons Pi1 and Pi2 controlling the tilting swash plate are connected with the tank, thus not allowing the force (Fp) that presses the...
  • Page 573 At High Speed When you turn on the travel 2-speed switch, this will actuate pilot pressure, which will move spools as shown on the following figure. Then, pressurized oil will flow into ports M1, M2, Pi1 and Pi2, having motor driving forces (P1: high-pressure, low-pressure)

  • Page 574: Parts List

    PARTS LIST Hydraulic Motor Figure 9 Travel Motor SP001686 Page 16...
  • Page 575 Reference Reference Description Description Number Number Hydraulic Motor Rear Flange Shaft Valve Seat Swash Plate Valve Cylinder Block Spring Piston Plug Shoe Ring Retainer Plate Spool Thrust Ball Plug Timing Plate Stopper Washer Plug Piston Valve Spring Spring Spring Spring Friction Plate O-ring Mating Plate...

  • Page 576: Reduction Gear

    Reduction Gear Figure 10 Travel Motor SP001686 Page 18...
  • Page 577 Reference Reference Description Description Number Number Ball Bearing Spindle Tapered Roller Bearing Hold Flange Needle Roller Bearing RV Gear Retaining Ring for Shaft Input Gear Retaining Ring for Shaft Spur Gear O-ring Cover O-ring Crank Shaft O-ring Spacer Floating Seal Plug Ring Hex Head Bolt...

  • Page 578: Special Tools And Materials

    SPECIAL TOOLS AND MATERIALS Standard Tools Name Description Applicable Parts Dial Type, Approx. 180N 33, 221, 226, 243, 280, 252, 254, 224, 34 Torque Wrench Dial Type, Approx. 560N 19, 35 Nominal 4 mm Nominal 5 mm Hexagon Wrench Nominal 6 mm Nominal 8 mm 33, 34, 226 Nominal 1/4 mm...

  • Page 579: Equipment And Materials

    Equipment and Materials Name Description Applicable Parts For Disassembling and General Work Stand Assembling Works Washing Tank For Washing Motor and Parts Press Capacity: 1960 N (200 kg•m) Press 104, 149 (1,446 ft lb) Volume: 20 x 20 x 20 in Heating Tank (500 x 500 x 500 mm) Heating Capacity: Over 100°C (212°F)

  • Page 580: Manufacturing Tools

    Manufacturing Tools Travel Motor Workbench Workbench for easily and safely disassembling and assembling the travel motor. Figure 11 Fixture For connecting spindle (2) and hub (1). Figure 12 Holder (I) For inserting spring (114), washer (110) and retaining ring (145) into cylinder block (104).
  • Page 581 Holder (IIII) For press fitting oil seal (132) into the oil seal hole the spindle (2). Figure 15 Holder (IV) For installing the RV gear assembly on spindle (2). Figure 16 Steel Rod For removing ring (18) from hub (1). For removing ring (265) from rear flange (201).
  • Page 582 Aluminum Rod For disassembling oil seal (132) from spindle (2). For removing ball bearing (21) and pin (17) from hub (1). Figure 19 PF Eye Bolt For lifting cover (8). Figure 20 Eye Bolt For lifting the GM motor, hub (1) ad spindle (2). "A"...
  • Page 583 F/S Installation Tool (II) For installing floating seal (31) to hub (1) and spindle (2). Figure 23 F/S Installation Tool (III) For installing floating seal (31) to spindle (2). Figure 24 Cover Removable Tool For removing cover (8) from hub (1). Figure 25 Slice For removing timing plate (109) from rear flange (201).

  • Page 584: Tightening Torque

    Tightening Torque Screw Part No. Name Width Across Flat Tightening Torque Dimension 25.7 ±4.0 kg•m (252 ±39.2 Nm) Reamer Bolt M16 (P2.0) 24 mm (186 ±29 ft lb) 6.0 ±1.0 kg•m Plug PF 3/8 8 mm (58.8 ±9.8 Nm) (43 ±7 ft lb) 6.0 ±1.0 kg•m Hexagon Socket Plug PF 3/8...

  • Page 585: Travel Motor Troubleshooting

    TRAVEL MOTOR TROUBLESHOOTING Travel Motor Applicable Parts Component Weight Motor Does Not Turn Defective of motor, counter balance Check suction pressure valve, decelerator, etc. Major components of motor broken Replace abnormally abraded parts. Remove surface scratches, burrs and reinstall. Replace damaged parts Motor Rotates Slow Insufficient oil pressure or quantity Check oil level in tank...

  • Page 586: Relief Valve

    Relief Valve Applicable Parts Component Weight No or Slow Rotation Defective relief valves seats. Remove foreign objects. Foreign objects in relief valve. Replace spring. Broken spring. Pressure too low to over come relief Replace relief valve. valve set pressure. Remove foreign objects. Loose spring.

  • Page 587: Disassembly

    DISASSEMBLY Preparations Perform the following preparations before disassembling. Workbench Preparations Provide a travel motor workbench. Provide a sturdy workbench with which the internal parts of the travel motor can be disassembled or assembled, is wide enough to place parts so they do not move or fall off the bench while working.

  • Page 588: Disassembly Procedure

    If you leave parts disassembled or partially disassembled, rust could develop on the parts due to moisture or dirt. If you have to interrupt work before completion, be careful to take measures to protect against rust or dust. Place a counter mark on mating faces of parts when disassembling.
  • Page 589 GM Motor Installation Set the GM motor on a workbench. NOTE: While matching the screw holes of hub (1) and screw holes of the workbench, carefully place the travel motor in the mounting holes of the workbench. Figure 29 Mount the GM motor on workbench so that the 2 hex socket head bolts are positioned symmetrically.
  • Page 590 Cover Removal Turn the work bench so cover (8) is on top. Paint match marks on cover (8) and hub (1). Look into the seem to locate the gap of ring (18). Remove ring (18) using a steel rod. CAUTION Be careful when removing the ring.
  • Page 591 Pick the end portion of the ring and pull it out to remove the ring off the groove. Figure 37 Remove cover (8) from hub (1) making use of the cover removable tool. Remove O-ring (29) from cover (8). NOTE: O-ring (29) might prevent the cover from sliding out.
  • Page 592 Spur Gear Removal Take out two retaining rings (25) from crank shaft (9). CAUTION Be careful when removing the retaining ring. You could become injured if tip of the pliers comes out of the retaining ring hole, and the retaining ring jumps out.
  • Page 593 Remove hex. socket bolts (243) (6 bolts) from spindle (2). NOTE: Be sure loosen the last two bolts slowly. Figure 45 Remove rear flange (201) from spindle (2). NOTE: Hold the rear flange with both hand, and gently lift it straight up; be careful not to cock it while lifting.
  • Page 594 Removing Parts from the Rear Flange Lay removed rear flange on the workbench, with its inner face up. Remove timing plate (109) from rear flange (201). NOTE: The timing plate might be found stuck to mating face of the rear flange. To separate timing plate, insert a flat bar into groove of rear flange and raise the timing plates slowly.
  • Page 595 Disassembly of Plugs Inside Rear Flange Remove two plugs (224) from rear flange (201). Figure 51 From each of the two holes, take out spring (228) and stopper (225). Remove spool (223) from rear flange (201). NOTE: To remove, tilt rear flange to let the spool slide down, catch the spool and slowly pull it out.
  • Page 596 Remove O-ring (236) from plug (224). NOTE: Do not reuse O-ring which has been removed. Figure 55 Remove O-ring (237) from plug (226). NOTE: Do not reuse O-ring which has been removed. Figure 56 Disassembling Valve (For 2-Speed Control) Press and hold down stopper (264) using a steel bar, and in that state, as shown in the diagram, press the notch in ring (265) using a sharp pointed steel bar.
  • Page 597 Remove Hexagon Socket Plug You may remove plug (252) but may not disassemble it unless absolute necessary. If the plug is blocked by dirt or any other foreign material, remove it and clean the oil gate. Be careful not to drop steel ball (268). Disassembling Valve for Parking Brake Press and hold down valve seat (218) using a steel bar, and in that state, as shown in the diagram, press the notch...
  • Page 598 Disassembling Parking Brake Remove piston (212) by injecting compressed air into the access hole in the spindle. CAUTION The abrupt injection of compressed air could cause the piston to pop up. To ensure your safety, hold a protective cover over the piston. Figure 61 Take out O-rings (235, 239) from the piston.
  • Page 599 Remove the piston assembly (piston (105), shoe (106)) from cylinder block (104). NOTE: When removing, grip retainer plate (107) with both hands and remove together with the retainer plate. The piston assembly is a minimum unit. If replacement is necessary, replace the piston assembly as one unit.
  • Page 600 Removal of Spring Inside Cylinder Block Place cylinder block (104) on the press bench. NOTE: The spring is removed only when replacing. The spring is removed by lining up the shaft centers of holder (I) and washer in order to prevent damage to the cylinder block through contact.
  • Page 601 Remove piston assembly (161,162) injecting compressed air into the access hole in spindle (2). CAUTION Be careful that the abrupt injection of compressed air could cause the piston assembly to pop out. To ensure your safety, hold a protective cover over the piston assembly.
  • Page 602 Paint match mark between retaining rings (20) and hold flange (3). NOTE: The match marks are intended to ensure that hold flange and retaining rings are in their correct positions when assembled. Figure 76 Turn the work bench 90 degrees. Loosen reamer bolts (19).
  • Page 603 11. Paint mach marks across hold flange (3) and spindle (2). NOTE: The match marks are intended to ensure that the hold flange and spindle are in their correct positions when assembled. The four holes for the reamer bolts and hex. head bolts in the spindle are machined with the holed flange attached to the spindle.
  • Page 604 Removal of Ball Bearing, RV Gear Assembly, and Pin Remove floating seal (31) from hub (1). NOTE: When removing ball bearing (21), tap end face of the pins equally in 3 - 4 places around the circumference a little at a time so as not to wrench ball bearing (21).
  • Page 605 Pull out the outer rings of tapered roller bearings (22) from spindle (2). Figure 86 Disassembling Hold Flange Remove the outer rings of tapered roller bearings (22). NOTE: Remove the outer ring only when the ball bearing is to be replaced. Figure 87 Washing Separate hub (1), spindle (2), cover (8), and rear flange...
  • Page 606 Finish Washing Rinse the washed parts in a rinsing sink filled with clean kerosene by gently shaking each part in the kerosene. Figure 89 Using clean, lint free cloth, wipe each rinsed part to remove dripping kerosene. NOTE: Dry hub (1), spindle (2) and hold flange (3) by spraying with compressed air until they are dry and clean.

  • Page 607: Service Preparations

    SERVICE PREPARATIONS Follow these standards when disassembling and inspecting the GM motor. Handle the various parts carefully. Be especially careful not to damage the moving and sliding parts. Seals Once disassembled, all seals (O-rings, oil seals, floating seals) should be replaced with new ones even if no damage is observed.
  • Page 608 Service Part No. Part Name Phenomenon Standard Limit • Spline section is worn. • Inner surface of bore is worn too Cylinder block much. • Flaw ad unequal wear on sliding plate surface with timing plate (109). • There is clearance in shaft direction Clearance Clearance Piston assembly...

  • Page 609: Assembly

    ASSEMBLY Assembly, as a rule, assembly is carried out by performing the procedure for disassembly in reverse. Preparation Provide a workbench, tools, and materials in the same way as for “Disassembly” on page 1-29. General Suggestions When Working Pay the same attention as for general suggestions for “Disassembly”...

  • Page 610: Assembly Procedure

    Assembly Procedure NOTE: If assembling after replacing parts, preload adjustment of the ball bearing and shaft direction clearance adjustment of the taper roller bearing necessary. Before assembling, therefore, make sure the following parts have been replaced. Renewal parts required for preload adjustment of the ball bearing: Hub (1), spindle kit, ball bearing (21).
  • Page 611 Press fit the ball bearing (21) in the hub (1) with an aluminum rod and hammer. NOTE: Be sure to keep it true and square by shining the aluminum rod around and pushing it in just a little at each spot. Figure 93 Apply oil thinly on the outside circumference of the O-ring of the floating seal (31), and mount the floating seal in the...
  • Page 612 Install eyebolts to the spindle (2). Lift the spindle (2) with crane, and gently it into the hub (1). Figure 97 Fasten the fixture jig to the hub (1) and the spindle (2), and tighten them slowly and equally. Turn the workbench upside down. Figure 98 Mount RV Gear Assembly Install RV gear (4) In the hub (1).
  • Page 613 After applying lubricating oil to the pins (17) (24 pins) insert between the pin groove of hub (1) and gear teeth groove. Figure 101 Insert the ball bearing (21) in the hub (1). NOTE: The fit of the ball bearing (21) outer diameter and hub (1) inner diameter is press fit.
  • Page 614 Tightening Reamer Bolts and Hex. Socket Bolts Apply antiseize lubricant to the shank, and the adhesive to the reamer bolt (19). NOTE: If the reamer bolt is smeared with oil or grease, degrease it with a degreasing agent, clean it with solvent, and let it stand and get dry for ten minutes before applying adhesive to it.
  • Page 615 Install Retaining Rings Check if any spindle (2), hold flange (3), RV gear assembly, and the spacer (12) a newly replaced parts. NOTE: If none of them is a newly replaced part, go to the next step. If any of them is a newly replaced part, adjust the axial clearance of tapered roller bearing (22) before doing to the next step.
  • Page 616 Spur Gear Assembly Match the counter marks (Figure 111) of the spur gears (7) (2 gears) and mount on the crank shaft (9). NOTE: Insert the spur gears (7) (2 gears) on the crank shaft (9) by matching the counter marks (punch holes) (Figure 111) as shown in the Figure 111.
  • Page 617 Shaft Assembly Install ball bearing (149) by shrink fitting. To install, heat the ball bearing by keeping it immersed in heating equipment at 100°C ± 10°C (212°F ±50°F) for about ten minutes. NOTE: Wear thick leather groves in handling the heated ball bearing.
  • Page 618 Assembly of Cylinder Block Interior Insert washer (110), spring (114), washer (110) and retaining ring (145) in that order, into cylinder block (104). Place the cylinder block (104) on the press bench. CAUTION When mounting the retaining ring, if the tip of the pliers slips out of the hole or the retaining ring, the retaining ring could jump out.
  • Page 619 Install the cylinder block (104) to the shaft (102). Turn cylinder block (104) with your hands and make sure there is no looseness. Figure 121 Assembly of Parking Brake Section Turn the workbench 90 degrees. Install mating plate (269), friction plate (215) and mating plate (216) in that order in the inner circumference groove of the spindle (2) and the section in cylinder block (204).
  • Page 620 Assembly of Brake Valve Parts in Rear Flange Fit O-rings (237) to the each plugs (226). NOTE: Apply grease to the O-rings (237). Install the valve (227) and the spring (230) on the plugs (226) (2 plugs). At this time, apply grease and connect the valve, spring and plug by cohesion of the grease.
  • Page 621 Temporarily tighten the plugs (224). Figure 127 Assembly of Rear Flange Mounted Parts Put rear flange (201) on the workbench, with its inner face Insert valve (263) into rear flange (201). Figure 128 Install the spring (266) into the valve (263), and insert the stopper (264) on it.
  • Page 622 Apply hydraulic fluid to the ball bearing (150), and fit the ball bearing into the rear flange (201). Figure 131 Insert the parallel pins (241) (2 pins) in the pin holes of the rear flange (201). Figure 132 Apply grease to the mating face with the rear flange (201) of the timing plate (109).
  • Page 623 Connection of Rear Flange with Spindle Fit the O-rings (30, 27) in the O-ring groove of the spindle (2). NOTE: Fit the O-ring (30, 27) without applying grease. If assembled with grease applied, the grease may bleed from the mating face of the rear flange and the spindle when the travel motor is running.
  • Page 624 Tighten plugs (224) with specified torque. NOTE: Tightening torque: 20 ±1.5 kgf•m (196 ±14.7 Nm) (145 ±11 ft lb) Figure 138 Tighten plugs (226) with specified torque. NOTE: Tightening torque: 8 ±1 kgf•m (78.5 ±9.8 Nm) 8.0 kg•m (58 ±7 ft lb) Figure 139 Input Gear Assembly Turn the workbench upside down.
  • Page 625 Cover Assembly Fill the reduction gear with the specified quantity of lubrication oil. NOTE: Lubricating oil: 1 liter (0.26 U.S. gal.) Fit the O-ring (29) to the cover (8). NOTE: Apply grease to the O-ring (29). Figure 142 Place the cover (8) on the hub (1), make sure the match mark is in the same position as it was disassembled.
  • Page 626 Remove Assembled GM Motor from Workbench Turn the workbench upside down. Remove the hex.socket bolts (2 bolts) securing the GM motor to the workbench. Figure 146 Fasten the eyebolts (2 bolts) to the spindle (2). NOTE: Be sure that the two eyebolts are opposite to each other.
  • Page 627 Preload Adjustment of Ball Bearing NOTE: In order to ensure the proper life for the ball bearing (21), it is necessary to provide a certain preload. Therefore, if replacing a part that influences the amount of preload, temporarily assemble in accordance with the following procedure, and check the amount of preload.
  • Page 628 Adjusting Axial Clearance on Tapered Roller Bearing NOTE: If the following parts have been replaced, readjust the axial clearance or tapered roller bearing (22) selecting retaining rings (20) having a suitable thickness: Hub (1), Spindle (2), Hold flange (3), RV gear assembly, and snap rings (20).
  • Page 629 Lightly hammer the retaining ring (20) with a hammer and holder (IV). NOTE: Check whether the retaining ring has been reliably fitted in the spindle. Figure 151 Measure the clearance between retaining ring (20) and the outer ring of roller bearing (22) with a thickness gauge. Determine whether the thickness of the retaining ring is suitable.

  • Page 630: Performance Confirmation Test

    PERFORMANCE CONFIRMATION TEST • After servicing the GM motor, perform the following performance tests by the following procedure. Required Measuring Devices 2 pieces Pressure gauge for 35 kgf/cm (3.43 MPa) (498 psi) Graduated cylinder (for 5 liter) 1 pieces Stopwatch 1 pieces Test Procedure GM motor mounting/piping...

  • Page 631: Clearance Adjustment Part Dimensions

    CLEARANCE ADJUSTMENT PART DIMENSIONS Part Name Dimensions Retaining ring (20) Classification symbol Dimension (T) ≤ 1.75 mm < T 1.80 mm ≤ (0.07 in < T 0.0709 in) ≤ 1.80 mm < T 1.85 mm ≤ (0.0709 in < T 0.0728 in) ≤...
  • Page 632 Travel Motor SP001686 Page 74...
  • Page 633 SP001639 MAIN CONTROL VALVESP001639 Main Control Valve Edition 1 Main Control Valve SP001639 Page 1...
  • Page 634 MEMO Main Control Valve SP001639 Page 2...
  • Page 635 Table of Contents Main Control Valve Safety Precautions..........5 Applicable Models ..........5 Composition, Function and Operation ....6 Function of Control Valve ..........6 Operation of Main Section..........7 Disassembly ............9 Disassembly of Accessory..........9 Disassembly of Arm2, Bucket, Right Run, Left Run, Arm1, Dozer, Swing, Boom Swing Section........
  • Page 636 Operation............24 SPEC of Control Valve ........24 Failure and Troubleshooting....... 25 Overall Control Valve............. 25 Relief Valve..............26 Overall Pneumatic System ..........26 Main Control Valve SP001639 Page 4...

  • Page 637: Main Control Valve

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Main Control Valve SP001639 Page 5...

  • Page 638: Composition, Function And Operation

    COMPOSITION, FUNCTION AND OPERATION The control valve is located between pump, cylinder and motor on the oil pressure circuit. Each component within the main control valve operates and controls oil flowing from the main pump. Such control changes operation direction and speed of both cylinder and motor.

  • Page 639: Operation Of Main Section

    Arm 2 function If operating the arm cylinder, working oil from the P1 pump side (No.1 section) and the P2 pump side (No.6 section) are mixed by the outside pipe. Boom2 function When performing Lift Up operation on the Boom, working oil in the Boom2 section of the P2 pump group is mixed with Boom1 section through the inside passage of the control valve.
  • Page 640 Lower down operation (Figure 17) "Pa3" and "Pi1" port are connected and Lower Down pilot pressure applies to the "Pi1"port. Operation of the anti-drift plate enables to connect the spring room side of the poppet to the "DR1" port and make poppet opening status, and returning passage is obtained.

  • Page 641: Disassembly

    DISASSEMBLY Following care should be taken in disassembly: Make pressure of the actuator not fulfilled and stop engine. If disassembling with pressure fulfilled, it is dangerous as H/P oil may be discharged or parts may be taken out. Take out air pressure within the tank. If there is pressure within a tank, it is dangerous as oil may be discharged in disassembly.

  • Page 642: Disassembly Of Boom1 Section (Figure 30)

    Disassembly of Boom1 Section (Figure 30) Take off the cap of Combination No. (3) of Figure 30 by loosening a (13) socket head bolt (hexagonal hole subtense 5mm). Remove (4) spring seat, (6) spring (5) spring seat and (13) O-ring. Then take out the anti-drift valve Assy by loosening a (20) socket head bolt (hexagonal hole subtense 5mm).

  • Page 643: Take Off Of Load Check Poppet Type

    Take Off of Load Check Poppet Type By removing a tie-rod, take off load check and plug type before disassembling the valve housing. Types of poppet or plug are as follow: Arm2 : (10) Plug×2, (9) spring×2, (7) poppet, (Figure 28) (8) poppet Bucket : (10) Plug×2, (9) spring×2, (7) poppet,...

  • Page 644: Disassembly Of Valve Housing

    Disassembly of Valve Housing Take off the (2) tie-rod by loosening a nut (hexagonal subtense8mm), Combination No. (1) of Figure 27. Orderly disassemble the valve housing of each section. Disassemble parts on the matching surface of each section. Arm2 : No parts (Figure 28) Bucket : (14) O-ring...

  • Page 645: Cleaning

    CLEANING Completely clean all parts disassembled with a mineral oil. Place each part on a clean paper or cloth for drying and inspecting with compressed air. INSPECTION Inspect for any protruded part, scratched flaw, dented flaw and other defects on the whole surface. Check that the actual groove surface of the valve housing is smooth and that there are scraps, dented point and rust, etc.

  • Page 646: Assembly

    ASSEMBLY Be cautious of followings when handling O-rings (or seals) for assembly: There should not be defect in forming or groove occurred when handling O-ring. Sufficiently apply grease or working oil, etc to the system part of O-ring and O-ring. The O-ring should not be stretched so that warping does not occur.

  • Page 647: Assembly Of Arm2, Bucket, Right Run, Left Run, Arm1, Dozer, Swing, Boom2/Aux, Boom Swing

    Assembly of Arm2, Bucket, Right Run, Left Run, Arm1, Dozer, Swing, Boom2/Aux, Boom Swing Insert (6) spring between Combination No. (4), (5) spring seat of Figure 28, Figure 29, Figure 30, Figure 33, Figure 35, Figure 36, Figure 37, Figure 38, and insert the spool into the (1) valve housing with same position and direction as before- disassembly, and then mount the (3) cap with the O-ring mounted with a (13) socket head bolt (hexagonal hole subtense...

  • Page 648: Inserting Of Load Check

    Inserting of Load Check Insert following load check, spring, plug (equipped with O-ring ). Arm2 : (10) Plug×2, (9) spring×2, (7) poppet, (8) poppet (Figure 28) Plug Tightening torque: 30.4~32.4N•m (hexagonal subtense 14mm) Bucket : (10) Plug×2, (9) spring×2, (7) poppet, (8) poppet (Figure 29) Plug Tightening torque:...

  • Page 649: Accessory Adherence

    Accessory Adherence Adhere (15), (16), (17) Relief valve assembly according to Combination No. of Figure 27. Tightening torque: 69 ~ 78 N•m CAUTION Slowly insert the spool straightly to the hole. Poor operation of the spool may occur if inserting the spool when there is non-smooth or irregular feeling by operating the spool manually after inserting the spool.

  • Page 650: Relief Valve

    RELIEF VALVE Main Relief Valve (P1, P2, P3) Operation The main relief valve is laid between neutral passage "HP" and low pressure passage "LP" and operates as follow: Figure 1 Oil fills the inside space "D" room through the throttle hole of the main poppet "C"...
  • Page 651 Hint for Disassembly and Assembly of Main Relief Valve Figure 4 Disassembly For the original product, replace assembly. When replacing, loosen hexagonal subtense24) with a spanner, etc and take off the O-ring (2, Figure 4). If oil leaks from the adjuster part (3, Figure 4), loosen the adjuster part and replace the O-ring (4, Figure 4).

  • Page 652: Overload Relief Valve

    Overload Relief Valve Overload Relief Valve This relief valve is inserted between the cylinder port "HP" and the low pressure passage "LP". Oil fulfills the inside space (G) through a hole of the piston (C). the sleeve (K) and the main port (D) are firmly seated by which it applies to other area of (A), (B).
  • Page 653 Suction Operation The anti-void unit is equipped with In the cylinder port "HP", which supplies oil when cavitation occurs. When pressure of the cylinder port "HP" is lower than "LP" in the low pressure side, the sleeve (K) opens by difference in the area between <A>...

  • Page 654: Pressure Adjustment Of Relief Valve

    Assembly Properly check that there are no scraps, primer pieces, etc around cam (1) screw part, and insert a new O-ring (2). After properly clean the relief mounting part of the valve housing, mount the relief valve and then tighten cam (1: hexagon subtense 23) to tightening torque of 69 ~ 78N•m.
  • Page 655 Main Relief Valve (P1, P2, P3) Read value of the pressure gauge in the end of the cylinder stroke by replacing the spool of the control valve as 1). Turn adjuster clockwise until required pressure will be obtained. 17.7MPa/rotation of adjuster rises. When reaching to the specified pressure, press the adjuster so that it should not rotate and tighten the lock nut.

  • Page 656: Mounting

    MOUNTING Be careful so that force will not be unnecessarily applied to pipe. Tighten all mounting bolts to the same torque. Take care as welding work near the valve may cause seal, etc by excessive heat or sputter, Always perform handling to prevent damage of each part until piping for prevention of scraps ingression.

  • Page 657: Failure And Troubleshooting

    FAILURE AND TROUBLESHOOTING Overall Control Valve Failure Possible Cause Troubleshooting Spool not subject to 1. Fluid temperature abnormally rises Remove the part that disturbs oil flow in stroke the pipe. 2. Working oil dirty Change working oil and wash circuits. 3.

  • Page 658: Relief Valve

    Relief Valve Failure Possible Cause Troubleshooting Pressure not rise 1. Main poppet sleeve or pilot poppet stuck open, or scraps are laid between valve seat parts Replace relief valve Instable relief 1. Pilot poppet seat damaged pressure 2. Piston or main poppet is stuck Abnormal relief 1.
  • Page 659 Figure 11 Arm2 Neutral Figure 12 Arm2 Crowd Main Control Valve SP001639 Page 27...
  • Page 660 Figure 13 Arm2 Crowd (simultaneous Operation with BOOM) Figure 14 Arm2 Dump Main Control Valve SP001639 Page 28...
  • Page 661 Figure 15 Boom1 Neutral Figure 16 Boom1 Lift Up Main Control Valve SP001639 Page 29...
  • Page 662 Figure 17 Boom1 Lower Down Main Control Valve SP001639 Page 30...
  • Page 663 Figure 18 Travel - R Neutral Figure 19 Travel - R Pb4 Main Control Valve SP001639 Page 31...
  • Page 664 Figure 20 Boom2 Neutral Figure 21 Boom2 Lift Up Joint Main Control Valve SP001639 Page 32...
  • Page 665 Figure 22 Arm1 (Reproduction Circuit) Figure 23 Arm1 (reproduction Circuit) Figure 24 Arm1 (reproduciton Circuit) dump Main Control Valve SP001639 Page 33...
  • Page 666 Figure 25 Straight Travel Neutral Figure 26 Straight Travel Operation Main Control Valve SP001639 Page 34...
  • Page 667 Figure 27 Reference Reference Description Description Number Number Spool Section Assembly Tie-Roo Spool Section Assembly Spool Section Assembly Relief Valve Assembly Spool Section Assembly Relief Valve Assembly Spool Section Assembly Relief Valve Assembly Spool Section Assembly Shutoff Valve Assembly Spacer Section Assembly Shipping Plug Spool Section Assembly Shipping Plug...
  • Page 668 Figure 28 Arm2 Reference Reference Description Description Number Number Valve Housing Poppet Spool Spring Plug Spring Seat O-ring Spring Seat O-ring Spring Socket Head Bolt Poppet Main Control Valve SP001639 Page 36...
  • Page 669 Figure 29 BKT Reference Reference Description Description Number Number Valve Housing Poppet Spool Spring Plug Spring Seat O-ring Spring Seat O-ring Spring Socket Head Bolt Poppet O-ring Main Control Valve SP001639 Page 37...
  • Page 670 Figure 30 Boom1 Reference Reference Description Description Number Number Valve Housing O-ring Spool O-ring Socket Head Bolt Spring Seat Poppet Spring Seat Spring Spring Spacer Anti-Drift Valve Assembly O-ring Poppet Backup Ring Spring Socket Head Bolt Plug Plug Assembly O-ring Main Control Valve SP001639 Page 38...
  • Page 671 Figure 31 T-R Reference Reference Description Description Number Number Valve Housing O-ring Spool O-ring Socket Head Bolt Spring Seat O-ring Spring Seat Poppet Spring Spring Plug Main Control Valve SP001639 Page 39...
  • Page 672 Figure 32 Inlet Reference Reference Description Description Number Number Valve Housing Spool Spring Plug Spring Seat O-ring Spring Seat O-ring Spring Socket Head Bolt Poppet Main Control Valve SP001639 Page 40...
  • Page 673 Figure 33 T-L Reference Reference Description Description Number Number Valve Housing O-ring Spool O-ring Socket Head Bolt Spring Seat O-ring Spring Seat Poppet Spring Spring Plug Main Control Valve SP001639 Page 41...
  • Page 674 Figure 34 Arm1 Reference Reference Description Description Number Number Valve Housing O-ring Spool Socket Head Bolt O-ring Spring Seat Poppet Spring Seat Spring Spring O-ring Poppet Plug O-ring Spring Plug O-ring O-ring Plug Main Control Valve SP001639 Page 42...
  • Page 675 Figure 35 Boom2/Aux Reference Reference Description Description Number Number Valve Housing Spring Spool Plug O-ring Spring Seat O-ring Spring Seat Socket Head Bolt Spring O-ring Poppet Plug Assembly Main Control Valve SP001639 Page 43...
  • Page 676 Figure 36 Dozer Reference Reference Description Description Number Number Valve Housing Spool Spring Plug Spring Seat O-ring Spring Seat O-ring Spring Socket Head Bolt Poppet O-ring Main Control Valve SP001639 Page 44...
  • Page 677 Figure 37 Boom Swing Reference Reference Description Description Number Number Valve Housing Spool Spring Plug Spring Seat O-ring Spring Seat O-ring Spring Socket Head Bolt Poppet O-ring Main Control Valve SP001639 Page 45...
  • Page 678 Figure 38 Swing Reference Reference Description Description Number Number Valve Housing Spool Spring Plug Spring Seat O-ring Spring Seat O-ring Spring Socket Head Bolt Poppet O-ring Main Control Valve SP001639 Page 46...
  • Page 679 Figure 39 Straight Travel Reference Reference Description Description Number Number Valve Housing Spool Plug O-ring Spring Seat Socket Head Bolt Spring Seat Filter-A Spring O-ring O-ring Name-Plate Screw Main Control Valve SP001639 Page 47...
  • Page 680 Main Control Valve SP001639 Page 48...
  • Page 681 SP001488 MAIN PUMP SP001488 Main Pump Edition 1 Main Pump SP001488 Page 1...
  • Page 682 MEMO Main Pump SP001488 Page 2...
  • Page 683 Table of Contents Main Pump Safety Precautions..........5 Applicable Models ..........5 General Description ..........6 Description of Ports............7 Operation Principle and Function of Components.. 8 Components of the Pump ..........8 Operation Principle ............11 Adjustment ............15 Installation ............
  • Page 684 MEMO Main Pump SP001488 Page 4...

  • Page 685: Main Pump

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX55 50001 and Up DX60R 50001 and Up Main Pump SP001488 Page 5...

  • Page 686: General Description

    GENERAL DESCRIPTION This is a capacity adjusting piston where two ports discharge oil to a single cylinder block. Although this is a double pump, it has a simple structure like a single pump. This pump is of a swash plate type and its tilt angle is like that of two pumps. The tilt angle of the pump changes the total pressure, P1 + P2.

  • Page 687: Description Of Ports

    Description of Ports Figure 2 Port Names Size/Standard Intake Port SAE 2 1/2 (Standard) A1, A2 Discharge Port G 3/4 (JIS B2351 O-TYPE) Discharge Port G 1/2 (JIS B2351 O-TYPE) A1G, A2G Gauge Port G 1/4 (JIS B2351 O-TYPE) Pilot Port G 1/4 (JIS B2351 O-TYPE) PB1, PB2 Pilot Port...

  • Page 688: Operation Principle And Function Of Components

    OPERATION PRINCIPLE AND FUNCTION OF COMPONENTS Components of the Pump • This is a capacity adjusting double piston pump which discharges oil into two ports from a single cylinder block. This being a single rotary group, it has a single intake port. Actuation oil is divided into two points by the control plate on the cover, where it is discharged into two discharge ports.
  • Page 689 Figure 3 Name Name Driving Axle Control Piston Tilting Plate Gear Pump Rotary Group Housing Cover Solenoid Valve Control Spring Relief Valve Main Pump SP001488 Page 9...
  • Page 690 2. Configuration of Solenoid Valves and Relief Valves This valve system consists of a body and solenoid valves, A and B. This is shielded by a cover and the relief valve to control pilot pressure is inside the cover. Figure 4 Reference Reference Description...

  • Page 691: Operation Principle

    Operation Principle Function of Pump • The cylinder block is joined together by a key groove and rotates along with driving axle. • The piston is assembled inside cylinder which operates in a reciprocal action along with surface of tilting plate. •...
  • Page 692 Figure 5 Control Function • Exhaust pressure P1 and P2 are determined by movement of tilting plate and piston. • Spring works direction against discharge pressure. • The set load of spring A (outer spring) decreases and tilting plate becomes fixed at maximum tilt position, when hydraulic pressure is applied to piston.
  • Page 693 Figure 6 Main Pump SP001488 Page 13...
  • Page 694 3. Control / Adjustment Procedure Loosen hex nuts. Tighten or release adjusting nuts for adjustment of the power changing curve. Figure 7 Reference Reference Description Description Number Number Spring Seat Release Cover Total Pressure Adjusting Nut Tighten Hex Nut Release Tighten Quantity of Oil Main Pump...

  • Page 695: Adjustment

    ADJUSTMENT Fine adjustment of the hydraulic pump is made possible by the input power and control. Readjustment of any and all adjusting parts may result in depriving them of control function and placing the pump off the certified specifications. Do not adjust adjusting nuts at your disposal.

  • Page 696: Procedures For Test Operation

    PROCEDURES FOR TEST OPERATION Make sure that the following shall be done before operating the engine: Check whether or not actuator oil tank is clean. Check whether or not pipe lines are well arranged and pump is installed to prevent tension. Check whether or not pipe lines are tightly secured, according to pipe line diagram.

  • Page 697: Maintenance And Protection

    23. Check whether or not pump and actuator gallery are operating properly. 24. Any irregular operation of actuator gallery indicates that air is still contained in the circuit. When all air is removed from circuit, then all parts will operate smoothly without any irregular motion and no foam will arise in actuator oil tank any longer.

  • Page 698: Checking Filters

    CHECKING FILTERS Check filters every day during the initial time of operation. Check them once a week until operation has become stabilized. Check them once a month after operation time exceeds 100 hours. CAUTION Check at the time of beginning operating whether or not filters are new after any part of the hydraulic system has been changed (for instance, additional part have been installed or pipelines have been replaced or repaired).

  • Page 699: Replacement Of Hydraulic Oil

    REPLACEMENT OF HYDRAULIC After 2,000 hours of operation. The replacement time period of every 2,000 hours or at other regular intervals may be shorten according to the degree of contamination and temperatures depending on the load condition of hydraulic oil. When hydraulic oil level is low or needs replacement, keep in mind the following: •...

  • Page 700: Diagnosis Of Troubles And Actions To Be Taken

    DIAGNOSIS OF TROUBLES AND ACTIONS TO BE TAKEN When a malfunction occurs, refer to the following table for the symptoms and perform the suggested actions to resolve the problem. Diagnosis of Troubles with the Pump Symptoms Causes Check Remedies Abnormal Air seeping into system due to Hydraulic oil level Refill hydraulic fluid...

  • Page 701: Solenoid Valve And Relief Valve

    Symptoms Causes Check Remedies Pressure The relief valve set pressure is Check circuit oil pressure Adjust relief valve Does Not Increase Oil Leaking from control valve Check the function of the Replace control valve and and actuator actuators and return line actuator pipes for overheating Poor pump efficiency...

  • Page 702: Disassembling And Reassembling Hydraulic Pump

    Symptoms Causes Check Remedies Oil Leakage Seal surface, packing or Check area around leak Replace seal O-ring damage and for abnormal pressure DISASSEMBLING AND REASSEMBLING HYDRAULIC PUMP Necessary Tools and Jigs Disassembling and reassembling hydraulic pump needs the following tools and jigs as shown below: Tools Names of Tools Quantity...

  • Page 703: Reminders For Disassembly And Assembly

    Be very careful not to damage any parts or allow any foreign objects to come into the parts being assembled. As a rule, do not reuse O-ring and oil seal, DOOSAN recommends to use new O-rings and oil seals. During assembly, always use a torque wrench to tighten all bolts and nuts to specified limits.

  • Page 704: Disassembling Procedure

    Disassembling Procedure Solenoid Valve Disassembly Remove hex socket head bolts (M8 x 30, 2 Each) by using a 6 mm Allen wrench. Figure 9 Gear Pump Disassembly Remove hex socket bolts (M10 x 25, 2 each) by using a 8 mm allen key. NOTE: Be careful not to damage O-rings on the gear pump.
  • Page 705 Main Pump Disassembly Remove cover. Remove Allen head bolts: (M14 x 40, 2 Each), (M14 x 65, 2 Each) and (M14 x 75, 2 Each). NOTE: Use Allen wrench (12 mm) Figure 13 Remove cover while keeping horizontal balance. There may be some resistance, while removing cover, so lightly tap cover with a plastic hammer.
  • Page 706 Rotary Group Removal Lay pump on its side, and remove rotary group from the axle. Figure 17 Axle Removal Remove retaining ring (C-type) (80) using an internal retaining ring pliers. Figure 18 Remove oil seal case and O-ring by using two screw drivers.
  • Page 707 Remove O-ring, seal, and bearing (outside wheel). Figure 21 Bearing (inside wheel) disassembly. Use a brass drift (10) and tap the underside of the bearing and remove. Figure 22 Remove tilting plate. Figure 23 Bearing (outside ring) disassembly. NOTE: Perform this disassembly only when necessary. Figure 24 Main Pump SP001488...
  • Page 708 Cover Disassembly Disassemble and remove control plate. Figure 25 Remove two plugs (GIA). Figure 26 Control piston disassembly Remove two spring seats, two springs and two parallel pins. Two conic plate spring and spring are between the two slotted taps and the piston. Mark the right and the left for differentiation, and place them on the right side.
  • Page 709 Disassembling Cylinder Using an Allen wrench (8 mm), remove Allen head bolts (M10 x 30, 2 Each). NOTE: Bolts are coated with Loctite #270. Disassemble them only when necessary. Figure 29 Disassemble the control spring. NOTE: Disassemble hex nuts only when necessary. Disengage hexagon bolts (M10 x 30, 2 Each) and remove cover by using an Allen wrench (8 mm).
  • Page 710 Remove adjusting screws. NOTE: Be careful not to lose the shim. Figure 33 Remove springs. Figure 34 Remove spools. Figure 35 Main Pump SP001488 Page 30...
  • Page 711 Gear Pump Disassembly Using an Allen wrench (6 mm), remove Allen head bolts (M8 x 45, 4 each). Figure 36 Remove side plate, backup ring, oblong cylindrical ring and gear. Figure 37 Remove idle gear. Figure 38 Gear pump (GSP2) disassembly Using a wrench (6 mm), remove hex socket bolts (M10 x 90, 4 each).
  • Page 712 Remove front cover. Figure 40 Disassemble the middle body. Figure 41 Remove molded O-rings. Figure 42 10. Disassemble plate, guide and O-ring. Figure 43 Main Pump SP001488 Page 32...
  • Page 713 11. Remove plate. Figure 44 12. Disassemble drive gear, idle gear and side plate. Figure 45 Disassemble Solenoid Valves Using an Allen wrench (8 mm), remove Allen head bolts (M4 x 10, 4 each). Figure 46 Remove solenoids. NOTE: Be careful not to drop the push rod. Figure 47 Main Pump SP001488...
  • Page 714 Remove spools. Figure 48 Remove O-rings. Figure 49 Remove springs. Figure 50 Main Pump SP001488 Page 34...

  • Page 715: Standard Values For Maintenance

    Standard Values for Maintenance Wash and dry all parts thoroughly before inspection. Inspect the critical parts carefully and replace those which are found to have abnormal abrasion or damaged by impact beyond their tolerance with new ones. Replace seals, if they are found to have noticeable deformation or damage.
  • Page 716 Control Plate • Check for any surface damage and replace if necessary Figure 54 Guide and Retainer • Check for any corrosion or uneven wear. If unsure, replace both guide and retainer as a set. • Minor corrosion or damage can be removed by lapping.

  • Page 717: Reassembly Procedure

    Reassembly Procedure Assembling Tilting Plate Install bearings (outside wheel) into housing. Figure 58 Coat backside of the plate with grease, and install tilting plate. Figure 59 Reference Description Number Shiny Surface Front Face Rear Face Figure 60 Install tilting plate into housing. Figure 61 Main Pump SP001488...
  • Page 718 Install bearings (both inside and outside wheels). Figure 62 Install seal and O-rings. Figure 63 Using an Allen wrench (8 mm), install Allen head socket bolts (M8 x 22, 4 each) to mount the plate. NOTE: Tightening Torque 28 - 35 Nm (2.9 - 3.6 kg•m) (21 - 26 ft lb) Figure 64 Main Pump...
  • Page 719 Assembling the Drive Axle Install axle into housing. Use a plastic hammer and tap key groove to position the bearing near the end of the housing. Figure 65 Lightly coat the O-rings with grease and install into housing. Figure 66 Place oil seal flat to the housing surface.
  • Page 720 Coat three parallel pins with grease and insert them into cylinder block. Figure 69 Assembling Rotary Group Install ten pistons into retainer. Figure 70 Coat inside of the guides with grease. Install guides between retainer and cylinder block and then insert pistons into cylinder block. Figure 71 10.
  • Page 721 Assembling Control Spring Coat control spring bores with grease before assembling. Figure 73 Install two springs (both internal and external). Figure 74 Install spring seat and insert control spring. Figure 75 Install cover with Allen head bolts. NOTE: Tightening Torque 55 - 69 Nm (5.6 - 7.0 kg•m) 40.5 - 50.5 ft lb) Figure 76 Main Pump...
  • Page 722 Install Allen head bolts (M10 x 30, 2 each) to mount cylinder. NOTE: Coat bolts with Loctite #270 before tightening. NOTE: Tightening Torque 55 - 69 Nm (5.6 - 7.0 kg•m) 40.5 - 50.5 ft lb) Figure 77 Install pistons. Figure 78 Engage a spring and a cone type plate spring (2 units).
  • Page 723 Install two plugs (GIA). NOTE: Tightening Torque 350 - 470 Nm (36 - 48 kg•m) (260 - 347 ft lb) Figure 81 Coat parallel pins with grease and insert into cylinder. Figure 82 10. Coat rear side of control plate with grease and align plate with key groove in cover and install onto block.
  • Page 724 Assembling Relief Valve Install spools. Figure 84 Insert springs into spool bore. Figure 85 Insert shim(s) into adjusting bolt. Figure 86 Insert adjusting bolt. Figure 87 Main Pump SP001488 Page 44...
  • Page 725 Tighten adjusting bolt. NOTE: After completing all assembly procedures tighten down adjusting bolt to torque of 9.8 Nm. Figure 88 Assembling of pickings. Place gasket on the housing surface and assemble the upper and lower halves of the pump together. NOTE: Be careful not to let aligning pins drop while assembling.
  • Page 726 10. Install bushings. Figure 92 11. Install couplings at the end of the main pump axle. Figure 93 12. Assemble main pump and gear pump. Figure 94 13. Using an Allen wrench, install hexagon bolts to hold the gear pump. NOTE: Torque 55 - 69 Nm (5.6 - 7.0 kg•m) (40.50 - 50.63 ft lb)
  • Page 727 Assembling of the Gear Pump Gear pump (GSP2) Install square rings on the side. Reference Description Number Intake Side Discharge Side Direction of Inserting Square Rings Figure 96 NOTE: Be careful not to reverse the directions of intake and exhaust sides. Figure 97 Install drive axle and idle gear on the side plate.
  • Page 728 Engage O-ring in guide, and then insert them into plate. Figure 100 Reference Description Number Face With Large Radius Guide Figure 101 Assemble plate, guide and O-ring. Figure 102 Assemble two plates. Be careful not to reverse the directions of the intake and exhaust sides. Figure 103 Main Pump SP001488...
  • Page 729 Reference Description Number Intake Side Discharge Side Figure 104 Install square ring. Figure 105 Insert two alignment pins into front cover. Figure 106 Install front cover. Figure 107 Main Pump SP001488 Page 49...
  • Page 730 Assembling Gear Pump (G1) Insert drive gear into housing. Figure 108 Insert idle gear. Figure 109 Coat square rings with grease. Assemble making certain the backup ring is in place. Figure 110 Install side plate (assembled in step 12), into housing. Figure 111 Main Pump SP001488...
  • Page 731 Install two aligning pins in the middle housing. Figure 112 Install O-ring into middle housing. Figure 113 Assemble the two middle housings. Figure 114 Install socket head bolts to secure housing. NOTE: Tightening Torque 29 Nm (3 kg•m) (21.70 ft lb). Figure 115 Main Pump SP001488...
  • Page 732 Insert aligning pins into the middle housing. Figure 116 10. Place the Gear Pump (GSP2) on its side and install coupling to the end of axle. Figure 117 11. Assemble two Gear Pumps (GSP2 and G1). Figure 118 12. Install Allen head bolts to secure the two gear pumps (GSP2 and G1).
  • Page 733 13. Install O-ring and filter in the front housing. Figure 120 Assembling Solenoid Valves Insert springs. Figure 121 Insert spools. Figure 122 Install O-rings. Figure 123 Main Pump SP001488 Page 53...
  • Page 734 Install solenoids. Figure 124 Install socket head bolts secure solenoid place.(M4 x 10, 4 each) NOTE: Tightening Torque 3 - 4 Nm (0.35 - 0.45 kg•m) (2.53 - 3.25 ft lb). Figure 125 Install O-ring. Figure 126 Mount solenoid assembly onto main pump using socket head bolts.
  • Page 735 SP001640 REMOTE CONTROL VALVE (WORK LEVER / JOYSTICK) SP001640 Remote Control Valve (Work Lever / Joystick) Edition 1 Remote Control Valve (Work Lever / Joystick) SP001640 Page 1...
  • Page 736 MEMO Remote Control Valve (Work Lever / Joystick) SP001640 Page 2...
  • Page 737 Table of Contents Remote Control Valve (Work Lever / Joystick) Safety Precautions..........5 Applicable Models ..........5 Structure Diagram ..........6 Parts List ............... 7 Performance Specification ........8 Hydraulic Pressure Circuit Diagram ..... 8 Disassembly and Assembly Tool ......9 Disassembly Method ..........
  • Page 738 MEMO Remote Control Valve (Work Lever / Joystick) SP001640 Page 4...

  • Page 739: Remote Control Valve (Work Lever / Joystick)

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Remote Control Valve (Work Lever / Joystick) SP001640 Page 5...

  • Page 740: Structure Diagram

    STRUCTURE DIAGRAM III-25 III-27 III-28 III-24 III-26 II-B-18 II-A-17 II-15 II-14 II-16 I-12 I-B-11 I-A-9 1-B-10 I-A-8 FG010350 Figure 1 Remote Control Valve (Work Lever / Joystick) SP001640 Page 6...

  • Page 741: Parts List

    PARTS LIST Part Name Standard Material Q’TY Remark Case J95C1001 Plug PT 1/8 SCM440 WPT18 Plug PF 3/8 J95C1002 O-Ring N,B,R PO 014 O-Ring P10A N,B,R PO 010A Spool Kit Port 1, 3 JA6H6011 Spool Kit Port 2, 4 JA6H6012 Spool J95C1003 Shim...

  • Page 742: Performance Specification

    PERFORMANCE SPECIFICATION PORT 1, 3 PORT 2, 4 22.9 21.8 Single Operating Torque Single Operating Torque 17.4 16.5 Secondary pressure Secondary pressure Push-ROD Stroke (mm) Push-ROD Stroke (mm) FG013465 Figure 2 HYDRAULIC PRESSURE CIRCUIT DIAGRAM FG011413 Figure 3 Remote Control Valve (Work Lever / Joystick) SP001640 Page 8...

  • Page 743: Disassembly And Assembly Tool

    DISASSEMBLY AND ASSEMBLY TOOL Part no. Tool Specification Remarks Driver - type Driver - type Small size Spanner 27 mm Spanner 22 mm III-26 Spanner 13 mm DISASSEMBLY METHOD Separate the HANDLE KIT (III) from the HEX NUT (23). Figure 4 Separate the BOOT (20) from the SWASH PLATE (22).
  • Page 744 Separate the HEX NUT (23) from the SWASH PLATE (22), and remove the SHAWH PLATE (22). Figure 6 Separate the JOINT ASS°ØY (11) from the BODY (1). Figure 7 Remove the PLATE (19) and separate the PLUG KIT ((II-A, II-B) from the BODY (1). Figure 8 Separate the BUSHING (29) from the BODY (1).
  • Page 745 Separate the SPOOL KIT (I-A, I-B) from the BODY (1). Figure 10 Figure 11 Separate SPRING (13) from the BODY (1). Figure 12 Figure 13 Remote Control Valve (Work Lever / Joystick) SP001640 Page 11...

  • Page 746: Assembly Method

    ASSEMBLY METHOD Assemble the SPRING (13) to the BODY (1). Figure 14 Figure 15 Assemble the SPOOL KIT (I-A, I-B). Assembly order : SPOOL(I-6) SHIM(I-7) → SPRING(I- SPOOL KIT(I-A) A-8) → SPRING SEAT(I-A-9) → STOPPER(I-12) SPOOL KIT(I-B) : SPOOL(I-6) SHIM(I-7) → SPRING(I- B-10) →...
  • Page 747 Install the BUSHING (29) on the BODY (1). Figure 18 Figure 19 Assemble the PLUG KIT (II-A, II-B). Assembly order PLUG KIT(II-A) : PLUG(II-14) → PUSH ROD(II-A-17) PLUG KIT(II-B) : PLUG(II-14) → PUSH ROD(II-B-18) Figure 20 Figure 21 Remote Control Valve (Work Lever / Joystick) SP001640 Page 13...
  • Page 748 Install the PLUG KIT (II-A, II-B) on the BODY (1). Figure 22 Install the PLATE (19). Figure 23 Assemble the BODY (1) to the JOINT Ass’y (21). Figure 24 Apply enough grease on the PUSH ROD and JOINT Ass’y part. Figure 25 Remote Control Valve (Work Lever / Joystick) SP001640...
  • Page 749 10. Insert the SWAH PLATE (22) and assemble the HEX NUT (23). Figure 26 11. Use the spanner to fixate the HEX NUT (23) firmly to the BODY (1). Figure 27 12. Install the BOOT (20) on the SWASH PLATE (22). Figure 28 Remote Control Valve (Work Lever / Joystick) SP001640...
  • Page 750 13. Assemble the HANDLE KIT (III) to the HEX NUT (23). Insert the wire in the BUSHING (29). Figure 29 Figure 30 Remote Control Valve (Work Lever / Joystick) SP001640 Page 16...
  • Page 751 SP001490 DOZER VALVE SP001490 Dozer Valve Edition 1 Dozer Valve SP001490 Page 1...
  • Page 752 MEMO Dozer Valve SP001490 Page 2...
  • Page 753 Table of Contents Dozer Valve Safety Precautions..........5 Applicable Models ..........5 Structure Diagram ..........6 Performance Specification ........7 Hydraulic Pressure Circuit Diagram ..... 7 Parts List ............... 8 Disassembly and Assembly Tool ......9 Disassembly ............9 Assembly Method..........11 Dozer Valve SP001490 Page 3...
  • Page 754 MEMO Dozer Valve SP001490 Page 4...

  • Page 755: Dozer Valve

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX55 50001 and Up DX60R 50001 and Up Dozer Valve SP001490 Page 5...

  • Page 756: Structure Diagram

    STRUCTURE DIAGRAM II-13 II-11 II-10 II-12 IV-3 FG010372 Figure 1 Dozer Valve SP001490 Page 6...

  • Page 757: Performance Specification

    PERFORMANCE SPECIFICATION Secondary Pressure Operating Torque Push-ROD Stroke (mm) FG011414 Figure 2 HYDRAULIC PRESSURE CIRCUIT DIAGRAM Symbol FG011415 Figure 3 Dozer Valve SP001490 Page 7...

  • Page 758: Parts List

    PARTS LIST Part Name Standard Material Q’TY Remark Body JA3H1001 Plug J96H2002 IV-3 O-ring N.B.R PO 08 Spring JAOL6001 Spool Kit JA6J8010 Spring Sea J96H2004 Spool J96H2005 Spring Sea AJV12D103 Spring JAOL6002 Stopper 2set AJV12D106 Plug Kit JA6J8011 II-10 Plug J96H2007 II-11 Rod Seal...

  • Page 759: Disassembly And Assembly Tool

    DISASSEMBLY AND ASSEMBLY TOOL Part no. Tool Specification Remarks Torque wrench L35 mm 150 Kgf/cm L wrench 10 mm L wrench 15 mm Spanner 8 mm DISASSEMBLY Separate the BOOT (22). Figure 4 Remove the PIN (17) and separate the LEVER (20). Figure 5 Dozer Valve SP001490...
  • Page 760 Loosen the fixated WRENCH BOLT (15) and separate the COVER (14). Figure 6 Separate the PLUG KIT (II) from the BODY (1). Figure 7 Separate the SPOOL KIT (I) from the BODY (1). Figure 8 Separate the SPRING (4) from the BODY (1). Figure 9 Dozer Valve SP001490...
  • Page 761 Separate the PLUG (2) from the BODY (1). Figure 10 Dozer Valve SP001490 Page 11...

  • Page 762: Assembly Method

    ASSEMBLY METHOD Assemble the PLUG (2) to the BODY (1). Figure 11 Assemble the SPRING (4) to the BODY (1). Figure 12 Assemble the SPOOL KIT (I). Assemble SPRING SEAT (I-5), SPRING (I-8), SPRING SEAT (I-5) STOPPER (I-9) to SPOOL (I-6) in this order. Figure 13 Assemble the SPOOL KIT (I) to the BODY (1).
  • Page 763 Assemble the PLUG KIT (II). Assemble the ROD SEAL(II-11), O-RING(II-12) and PUSH ROD(II-13) to the PLUG (II-10) in this order. Figure 15 Figure 16 Assemble the PLUG KIT (II) to the BODY (1). Figure 17 Dozer Valve SP001490 Page 13...
  • Page 764 Assemble the COVER (14) to the BODY (1). Figure 18 Figure 19 After assembling the LEVER20 (20) and GUIDE (16), then install it on the BODY (1) and fixate the assemble with the PIN (17). Figure 20 Figure 21 Dozer Valve SP001490 Page 14...
  • Page 765 Adjust the gap between the GUIDE (16) and PUSH ROD (II-13). Figure 22 10. Assemble the BOOT (22). Figure 23 Dozer Valve SP001490 Page 15...
  • Page 766 Dozer Valve SP001490 Page 16...
  • Page 767 SP001641 TRAVEL CONTORL VALVESP001641 Travel Contorl Valve Edition 1 Travel Contorl Valve SP001641 Page 1...
  • Page 768 MEMO Travel Contorl Valve SP001641 Page 2...
  • Page 769 Table of Contents Travel Contorl Valve Safety Precautions..........5 Applicable Models ..........5 General Description ..........6 Parts List................6 Performance Specification ........7 Hydraulic Pressure Circuit Diagram ..... 7 Maintenance ............8 Required Tool and Tightening Torque ......8 Maintenance Standard............
  • Page 770 MEMO Travel Contorl Valve SP001641 Page 4...

  • Page 771: Travel Contorl Valve

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Travel Contorl Valve SP001641 Page 5...

  • Page 772: General Description

    GENERAL DESCRIPTION Parts List FG013466 Figure 1 Reference Reference Description Description Number Number Casing (1) Socket Bolt Casing (2) O-ring RO Plug Plug PT Plug Cover Spool Packing Washer Grease Cap Washer Steel Ball Spring Bush Spring Cam Shaft Spring Seat Bellows O-ring Screw...

  • Page 773: Performance Specification

    PERFORMANCE SPECIFICATION 12.0 Operating Torque 10.75 6.08 1.95 5.70 4.35 0.54 Secondary pressure Push-ROD Stroke (mm) FG013468 Figure 2 HYDRAULIC PRESSURE CIRCUIT DIAGRAM FG013469 Figure 3 Travel Contorl Valve SP001641 Page 7...

  • Page 774: Maintenance

    MAINTENANCE Required Tool and Tightening Torque Tool Product number Product name Size Tightening Torque Remarks Torque- Socket Bolt 170±15 Wrench Screw 83±10 Po Plug PF1/4 300±20 Pt Plug NPTF1/16 70±10 Driver Nhu Packing Hammer Bush Cam Shaft Special tool Bush Others: •...

  • Page 775: Maintenance Standard

    Maintenance Standard Check item Standard Remarks Leakage Neutral: 500 cc/min or above Test condition: During operation: 1,000 cc/min or above * 1st pressure: 35 kg/cm Exchange according to above condition * Oil level: 23 cst * When there are 4 pressure drop valves Spool Exchange when the sliding part is worn off Leakage level is expected to be same...

  • Page 776: Disassembly

    Disassembly Preparation First, clean the exterior of the valve cleanly before the disassembly. Execute the disassembly process in a clean environment. Prepare the tool and material. General precaution during disassembly Because all parts are assembled with precision with permitted tolerance, special care is required not to damage these parts.
  • Page 777 Disassemble the cover (18) and cam (26) assemble from the casing [2] (2). Figure 7 Use the torque-wrench to unscrew the screws (25). NOTE: Be careful because the loosening torque can be high from the applied Loctite #242. Figure 8 Align the rot to one end of the cam shaft (23) and lightly use the hammer to disassemble it.
  • Page 778 Disassemble the casing [2] (2) from the casing [1] (1). Figure 11 Disassemble the push rod (14) from the plug (17). Figure 12 10. Disassemble the plug (17) from the casing [2] (2). Figure 13 11. Disassemble the grease cap (20) from the plug (17). Figure 14 Travel Contorl Valve SP001641...
  • Page 779 12. Disassemble the O ring (16) and dust seal (19) from the plug (17). Disassemble the dust seal with a small screw driver. Figure 15 13. Disassemble the piston (13) from the casing [2] (2). Figure 16 14. Disassemble the spring (12) from the casing [2] (2). Figure 17 15.
  • Page 780 16. Disassemble the spring (8) from the casing [1] (1). Figure 19 17. Disassemble the O-ring (11), (28) from the casing [1] (1). Figure 20 18. Press the spring sheet (10) down and disassemble it from the spool (5). Figure 21 19.

  • Page 781: Assembly

    Assembly Preparation Prepare the tool and parts, and assemble the valve at a location where it is clean and dust free. General precaution during reassembly It is the same as disassembly. Clean each part and remove any alien particles. Then check whether there are any rough marks and damages.
  • Page 782 Assemble the O-ring (11), (28) on the casing [1] (1). Figure 25 Assemble the return spring (8) on the casing [1] (1). Assemble the sub-assembled pressure drop valve assembly as shown above. NOTE: Assemble to its original location. Figure 26 NOTE: When installing the pressure drop valve sub- assembly, be careful not to hit the bottom part of...
  • Page 783 Assemble the spring (12) and piston (13) to the casing [2] (2). Figure 29 Assemble the O-ring (16) on the plug (17). Figure 30 Assemble the dust seal (19) on the plug (17). NOTE: Be careful of the direction of the dust seal during the assembly.
  • Page 784 Assemble the push rod (14) and plug (17) assembly to the casing [2] (2). Figure 34 10. Assemble the grease cap (20) on the plug (17). Figure 35 11. Press the bushing into the cover (18) using the special tool. NOTE: Be careful not to project the bush corner to the inner side.
  • Page 785 13. Assemble the cam (26) on the cover (18) and insert it on one end of the cam shaft (23). Figure 38 14. Apply Loctite #241 or equivalent material on the surface of the hexagonal hole set, and tighten it according to the regulated torque.
  • Page 786 17. Assemble the cover (18) on the casing [2] (2), and tighten the hexagonal socket bolt (15) according to the regulated torque. Figure 42 18. Insert the top of the bellows (24) to the groove of the cam, and insert the bottom of the screw into the groove of the cover.

  • Page 787: Troubleshooting

    TROUBLESHOOTING General Caution This describes the general caution that can be applied in case of a problem during the operation. When there is a problem, first check at which condition the problem occurred. Alien particles are very harmful to the hydraulic pressure device and adequate care must be put.
  • Page 788 Travel Contorl Valve SP001641 Page 22...
  • Page 789 SP001073 PEDAL VALVE SP001073 Pedal Valve Edition 1 Pedal Valve SP001073 Page 1...
  • Page 790 MEMO Pedal Valve SP001073 Page 2...
  • Page 791 Table of Contents Pedal Valve Safety Precautions..........5 Applicable Models ..........5 General Description ..........6 Parts List................6 Specifications..............7 Tools and Materials ..........7 Disassembly ............8 Assembly ............10 Pedal Valve SP001073 Page 3...
  • Page 792 MEMO Pedal Valve SP001073 Page 4...

  • Page 793: Pedal Valve

    Remember, that ultimately safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX27Z 5001 and Up DX35Z 5001 and Up DX60R 50001 and Up Pedal Valve SP001073 Page 5...

  • Page 794: General Description

    GENERAL DESCRIPTION Parts List Figure 1 Reference Reference Description Description Number Number Body Rod Seal Plug Push Rod O-ring Cover Spool DU Bush Spring Seat Wrench Bolt Spring Spring Seat Stopper Adjust Screw Spring Socket Bolt Plug Bellows O-ring Pedal Valve SP001073 Page 6...

  • Page 795: Specifications

    Specifications Performance 74.3 Operating Torque 30.2 Secondary Pressure PUSH-ROD STROKE (mm) FG008547 Figure 2 Hydraulic Circuit Diagram SYMBOL FG008548 Figure 3 TOOLS AND MATERIALS Tool Standard Remark L Wrench 10 mm L Wrench 5 mm L Wrench 3 mm L Wrench 2.5 mm Pedal Valve SP001073...

  • Page 796: Disassembly

    DISASSEMBLY Remove Bellows (21) from cover (14) and cam (17). Figure 4 Remove cam (17) from cover (14). Figure 5 Loosen wrench bolt (16) to remove cover (14) from body (1). Figure 6 Remove flug kit from body (1). Figure 7 Pedal Valve SP001073 Page 8...
  • Page 797 Remove spool kit from body (1). Figure 8 Remove spring (9) from body (1). Figure 9 Remove plug (2) from body (1). Figure 10 Pedal Valve SP001073 Page 9...

  • Page 798: Assembly

    ASSEMBLY Install plug (2) to be assembled o-ring (3) into body (1). Figure 11 Install spring (9) into body (1). Figure 12 Take care when assembling spool kits assemblies. They should be assembled in same way. The assembly order is spool (4), spring seat (5), spring (6), spring seat (7) and stopper (8).
  • Page 799 Takr care when assembling plug kits assemblies. They should be assembled in same way. The assemble order is : plug (10), rod seal (12), o-ring (11) and push rod (12) Figure 15 Install plug kit into body (1). Figure 16 Install DU bush into cover (14).
  • Page 800 Install adjust screw (19) socket bolt (20) into cam (17). Figure 19 10. Install cam (17) into the cover (14) . Holding down the cam (17), insert the pin (18) from outside. Figure 20 11. Set the cap (17) balance by the L wrench. Figure 21 12.
  • Page 801 13. Completd Assembly. Figure 23 Pedal Valve SP001073 Page 13...
  • Page 802 Pedal Valve SP001073 Page 14...
  • Page 803 SP001692 HYDRAULIC SCHEMATICSP001692 Hydraulic Schematic Edition 1 Hydraulic Schematic SP001692 Page 1...
  • Page 804 MEMO Hydraulic Schematic SP001692 Page 2...
  • Page 805 Table of Contents Hydraulic Schematic Safety Precautions..........5 Applicable Models ..........5 DX60R ..............7 Hydraulic Schematic SP001692 Page 3...
  • Page 806 MEMO Hydraulic Schematic SP001692 Page 4...
  • Page 807 Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Hydraulic Schematic SP001692 Page 5...
  • Page 808 Hydraulic Schematic SP001692 Page 6...
  • Page 809 DX60R TRAVEL(R) TRAVEL(L) BUCKET TONG-MYUNG TONG-MYUNG i=53.706 i=53.706 TM07VC TM07VC 39.8/23.4 39.8/23.4 cc/rev cc/rev PB(SWING PARKING) SWING MOTOR QUICK COUPLER i=15.5 Solenoid Valve BOOM CLAMSHELL BOOM SWING DOZER BOOM LOCK(OPT) 28.5cc/rev TONG MYUNG P2(FORWARD) P1(BACKRWARD) P1(FORWARD) P2(BACKWARD) TSM32(S)CAB-RG250D-1 200k OPTION V/V...
  • Page 811 Electrical System...
  • Page 813 SP001687 ELECTRICAL SYSTEMSP001687 Electrical System Edition 1 Electrical System SP001687 Page 1...
  • Page 814 MEMO SP001687 Electrical System Page 2...
  • Page 815 Table of Contents Electrical System Safety Precautions..........5 Applicable Models ..........5 Overview............... 7 Electrical Supply System ........8 Engine Starting ........... 10 Start Operation .............. 10 After Start ..............12 Engine Preheating System ......... 13 Engine Stop ............15 Charging System ..........
  • Page 816 Air-conditioning System Circuit Diagram ...... 38 Air Flow Control ............. 39 Air Flow Control Motor........... 40 Blower Motor ..............40 Coolant Flow Control Valve ........... 41 Temperature Level Control And Display ....... 42 Weight of R134a Gas Used in Machines ... 43 Refrigerant System Repairs........

  • Page 817: Electrical System

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up SP001687 Electrical System Page 5...
  • Page 818 Electrical System SP001687 Page 6...

  • Page 819: Overview

    OVERVIEW The electrical system for this equipment is DC 12 volts. The rated voltage for all electric components is 12 volts. The system contains one 12 volts battery and a three phase AC generator with a rectifier. The electric wiring used in the system is easily identifiable by the insulator color.

  • Page 820: Electrical Supply System

    ELECTRICAL SUPPLY SYSTEM The electric power circuit supplies electric current to each electric component. It consists of battery, starter switch fusible link and fuse box. The negative terminal of battery is grounded to negative body. Even when starter switch (5) is in "OFF" position, electric current is supplied to following components through battery (1) →...
  • Page 821 FG012303 Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Reference Description Description Number Number Battery Starter Switch Battery Relay Fuse Box Fusible Link Alternator Circuit Breaker Electrical System SP001687 Page 9...

  • Page 822: Engine Starting

    ENGINE STARTING Start Operation When the starter switch (6) is turned to the ON position, the ECU (9) performs rack self diagnostics directly. At this time, the starter relay prevents the starter motor from starting until the diagnostics is completed. When the starter switch (6) is turned to the START position, the contacts in the starter relay (11) are closed by the current flow from battery (1) →...
  • Page 823 ENGINE SPEED GND-RPM SENSOR CSD COIL GND-A RACK ACTUATOR STARTER SWITCH CONNECTION BR R1 R2 C ACC START FG011497 Figure 2 STARTER CIRCUIT Reference Reference Description Description Number Number Battery Rack Actuator Relay Battery Relay Engine Control Unit Fusible Link Fuel Injection Pump Circuit Breaker Starter Relay...

  • Page 824: After Start

    After Start when the engine speed goes over 675 rpm, the connection between "20" and "ground" terminals of ECU (9) and the connection between "30" and "87" terminals of starter relay (11) are opened. As a result the rotation of the starter (12) is stopped. Once the engine is running, the starter (12) will not operate even if the starter switch (6) is moved to the start position, preventing possible damage to the starter.

  • Page 825: Engine Preheating System

    ENGINE PREHEATING SYSTEM An air heater (12) is installed in the intake manifold of the engine. When the starter switch(6) is turned "ON" position, the current flows from the battery (1) → fusible link (3) → fuse box (5) → "B" terminal of starter switch (6) →...
  • Page 826 STARTER SWITCH CONNECTION BR R1 R2 C ACC START ENGINE SPEED GND-RPM SENSOR CSD COIL GND-A RACK ACTUATOR FG011498 Figure 4 ENGINE PREHEAT CIRCUIT Reference Reference Description Description Number Number Battery Engine Control Unit Battery Relay Fuel Injection Pump Fusible Link Preheat Relay Circuit Breaker Air Heater...

  • Page 827: Engine Stop

    ENGINE STOP When the starter switch (6) is turned "ON" position, the ECU (9) is activated. The ECU(9) controls the rack actuator in the fuel injection pump(10) to control the fuel deliver rate. When the start switch (6) is turned "OFF" position, the ECU(9) stops suppling power to the rack actuator relay (8).

  • Page 828: Charging System

    CHARGING SYSTEM When the starter switch (6) is turned "ON" position, an initial excited current flows to the field coil of alternator (7) through the battery (1), battery relay (2) and circuit breaker (4). When the engine is started from this condition the alternator (7) starts charging.

  • Page 829: Instrument System

    INSTRUMENT SYSTEM Instrument Panel The instrument system displays the equipment conditions and warning signals onto the instrument panel by processing the information gathered from the various sensors throughout the equipment. CHECK FG010730 Figure 7 Reference Reference Description Description Number Number Engine Coolant Temperature Gauge Fuel Level Warning Light Fuel Gauge...

  • Page 830: Function Check

    Connector and Terminal Number FG011463 Figure 8 Function Check When the starter switch is turned to the "ON" position, all indicator lights and warning lights will be lit for 2 seconds and the warning buzzer will sound. If there is any light that does not go on during the function check, replace or repair.

  • Page 831: Operation

    OPERATION Gauge Sensor Specification Function Display Input Terminal Input Specification White 50°C - Over 188.2Ω Engine 67°C - 102Ω Coolant 105°C - 32Ω Temperature 125°C - below 19.8Ω AXO0280L White Empty - Over 90Ω Fuel Quantity 1/2 - 38Ω Full - below 10Ω AXO0290L SP001687 Electrical System...

  • Page 832: Warning Lights

    Warning Lights Input Description Symbol Operation Remarks Terminal After starting engine, Lights up when oil if engine oil pressure Engine pressure drops below is insufficient after 8 Pressure seconds, a warning 0.5 kg/cm buzzer will sound. HAOA620L Under normal Lights up when not condition, it will light charging.
  • Page 833 Input Description Symbol Operation Remarks Terminal Lights up when the High Speed high speed switch turns "ON". FG010190 It lights when work light Work Light turns "ON". HB4O2003 Lights up when water Water quantity is increased in Fuel the water seperator. FG010520 Lights up when the Quick...

  • Page 834: Circuit Diagram Of Instrument Panel

    Circuit Diagram of Instrument Panel W/T GAUGE FUEL GAUGE ILLUMINATION WATER SEPERATOR AIR CLEANER FUEL EMPTY ENG OIL PRESS WATER TEMP. CHARGE OVER LOAD QUICK CLAMP PREHEAT HIGH SPEED ENGINE WARNING WORKING LAMP FG011500 Figure 9 Reference Reference Description Description Number Number Battery...

  • Page 835: Control Unit Circuit

    Control unit circuit W/T GAUGE FUEL GAUGE ILLUMINATION AIR CLEANER FUEL EMPTY WATER SEPARATOR ENG OIL PRESS WATER TEMP. CHARGE OVER LOAD QUICK CLAMP PREHEAT HIGH SPEED E/G WARNING WORKING LAMP FG011501 Figure 10 Reference Reference Description Description Number Number Battery Alternator Battery Relay...

  • Page 836: Performance Specification

    Performance Specification Input Output All warning lights and warning buzzer are Starter switch "ON" turned on and turned off after approximately 2 seconds. High speed switch "ON" "L7" turned on Starter switch "ON" Quick clamp switch "ON" "L13" and pilot buzzer turned on Starter switch "ON"...

  • Page 837: Engine Control Dial

    ENGINE CONTROL DIAL 7th STEP 13th STEP 1st STEP ( 10 ) ( 10 ) MECHANICAL MECHANICAL STOP STOP 4.0V 2.5V 1.0V SETUP 1ST 2nd 12th 13th STOP STOP VIEW ( POTENTIOMETER BOTTOM) HDA6033L Figure 12 Reference Reference Description Description Number Number Knob...

  • Page 838: Engine Control Circuit Diagram

    Engine Control Circuit Diagram HIGH ENGINE SPEED GND-RPM SENSOR CSD COIL GND-A RACK ACTUATOR FG011494 Figure 13 Reference Reference Description Description Number Number Battery Main Relay Battery Relay Rack Actuator Relay Fusible Link ECU (Engine Control Unit) Fuel Injection Pump Circuit Breaker Fuse Box Engine Control Dial...

  • Page 839: Automatic Deceleration Control (Auto Idle Control)

    Automatic Deceleration Control (Auto Idle Control) Figure 15 Reference Reference Description Description Number Number Engine Control Dial Auto Idle Pressure Switch Auto Idle Select Switch ECU (Engine Control Unit) If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed is automatically lowered.

  • Page 840: Engine Overheat Protection System

    Engine Overheat Protection System Figure 16 Reference Reference Description Description Number Number Engine Control Dial ECU (Engine Control Unit) Instrument Panel Pilot Buzzer Engine Coolant Temperature Sensor The ECU detects engine coolant temperature from the sensor mounted in the coolant line. When the engine coolant temperature increases to over 110°C, the overheat warning light in the instrument panel will be turned on and the pilot buzzer sounds simultaneously.

  • Page 841: Engine Control Unit

    Engine Control Unit WATER TEMP. ENGINE WARNING PREHEAT HIGH 25bar CAN-L 120ohm CAN-H ENGINE SPEED GND-RPM SENSOR CSD COIL CN5-1 CN5-2 CN5-5 CN5-4 CN5-6 GND-A RACK ACTUATOR CN6-2 CN6-1 CN6-4 CN6-3 FCI 48P CN6-6 CN6-5 FG011503 Figure 17 Reference Reference Description Description Number...

  • Page 842: Control Failure Detection

    Control Failure Detection The E-ECU performs various self-diagnostics. Diagnostic items are divided into "Always enable", "Default to enable" and "Default to disable" in the table. Diagnostic list Action/ Number Failure detection Item Operation when failure occurs condition for Category conditions recovery flashes Coolant...
  • Page 843 Action/ Number Failure detection Item Operation when failure occurs condition for Category conditions recovery flashes Backup speed Engine start signal Engine continues to run while main speed Turn key off. sensor failure (E8) is on, but the sensor is used. engine speed Backup speed sensor failed : Engine stops.
  • Page 844 Action/ Number Failure detection Item Operation when failure occurs condition for Category conditions recovery flashes Sensor Monitoring voltage is Engine runs normally. Turn key off. failure approx. 0 V. Monitoring voltage is Always 4.5 V or less. enable Monitoring voltage is 5.5 V or more.

  • Page 845: Flashing Patterns Of Engine Check Lamp

    Flashing patterns of engine check lamp When detecting these failures, the E-ECU (Engine control unit) flashes the engine check lamp to alert the operator to the occurrence of failure conditions. The engine check lamp will illuminate for 2 sec. when the E-ECU is power on. This allows checking if the E-ECU is supplied with power normally.

  • Page 846: Fuel Injection Pump

    FUEL INJECTION PUMP Figure 19 Electrical System SP001687 Page 34...

  • Page 847: Egr Valve

    EGR VALVE Figure 20 SP001687 Electrical System Page 35...

  • Page 848: Refrigerant Circulation

    REFRIGERANT CIRCULATION HBOI020L Figure 21 Reference Reference Description Description Number Number Evaporator Compressor Expansion Valve Blower Fan Condenser Receiver Dryer Condenser Fan Electrical System SP001687 Page 36...
  • Page 849 Shading Temperature Refrigerant State High High-pressure Gas High High-pressure Liquid Low-pressure Liquid High High-pressure Gas/Liquid Low-pressure Gas • Refrigerant (R134a) is compressed to approximately 15 kg/cm (210 psi) within the compressor. • The compressed refrigerant flows into the condenser at high temperature (approximately 80°C (176°F)). •...

  • Page 850: Air-Conditioning System Circuit Diagram

    Air-conditioning System Circuit Diagram OPEN CLOSE LOW PRESS HIGH PRESS CUT OFF CUT OFF OPEN CLOSE FOOT DEF. WARM COOL (HI) (MID) (LOW) FG010308 Figure 22 Reference Reference Description Description Number Number Battery Condenser fan Battery relay Receiver dryer Circuit breaker Blower relay Fusible link Compressor relay...

  • Page 851: Air Flow Control

    Air Flow Control Air flow control motor(A) Air flow control motor(C) Air flow control motor(B) Blower motor FG011507 Figure 23 Air flow control motor (A) Air flow control motor (B) Air flow control motor (C) Open Open Close Close Open Close Close Open...

  • Page 852: Air Flow Control Motor

    Air Flow Control Motor Figure 24 Blower Motor Figure 25 Electrical System SP001687 Page 40...

  • Page 853: Coolant Flow Control Valve

    Coolant Flow Control Valve Figure 26 SP001687 Electrical System Page 41...

  • Page 854: Temperature Level Control And Display

    Temperature Level Control And Display Position Step LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Sensor Remark Voltage Green Green Green Green Green Green Green 4.50V ± 0.2 MAX. COOL Green Green Green Green Green Green Green...

  • Page 855: Weight Of R134A Gas Used In Machines

    Weight of Gas DX35Z 450 ± 20 gram (15.9 ± 0.7 oz) DX55 500 ± 20 gram (17.6 ± 0.7 oz) DX60R 550 ± 20 gram (19.4 ± 0.7 oz) DX80R 650 ± 20 gram (22.9 ± 0.7 oz) SP001687...

  • Page 856: Refrigerant System Repairs

    REFRIGERANT SYSTEM REPAIRS WARNING Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately flush with clean, running water and consult a physician. Select a clean and well-ventilated area to work. The refrigerant container is under high-pressure and should be stored below 40°C (104°F).

  • Page 857: Repair And Replacement Procedure

    Do not over tighten connections when working on refrigerant system. The new refrigerant system standards require new tools, equipment and parts. Do not attempt to use equipment use in servicing the old refrigerant system. The new refrigerant oil (PAG type) has a high moisture absorption characteristic.
  • Page 858 INSTALL REPAIR TOOL RECOVER REFRIGERANT REPAIR / REPLACE DEFECTIVE PARTS VACUUM SYSTEM (OVER 5 MINUTES) CHECK SYSTEM FOR AIR LEAKAGE REPAIR VACUUM SYSTEM (OVER 20 MINUTES) CHARGE SYSTEM (APPROXIMATELY 100 g) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL (Standard Capacity less Initial Charge) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL...

  • Page 859: Refrigerant Recovery

    Refrigerant Recovery Reference Number Description To Compressor Low-pressure Side High-pressure Side From Receiver Refrigerant Recovery Tank Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. HDA6067L NOTE: Be careful not to switch the connections for the Figure 29 low and high-pressure valves.
  • Page 860 Check system for vacuum leak; Allow system to sit for 10 minutes and check whether the system is holding the pressure. If the pressure has dropped, it must be repaired before proceeding to the next step. Vacuuming Procedure; NOTE: If the system is holding the pressure and it has not changed for 10 minutes, vacuum out the system for an additional 20 minutes.

  • Page 861: Leakage Check

    Leakage Check NOTE: Perform the leakage check after completing vacuuming process. After attaching the manifold gauge, open the high side valve. Charge system until the low side gauge dial indicates a pressure of 1 kg/cm (14 psi) and close the high side valve.
  • Page 862 If refrigerant does not flow freely into system, try starting engine first before operating air conditioner. • Temperature control switch setting: Maximum Cooling. Blower Speed Setting: Hi (3 step). Engine Speed: 1,300 - 1,500 rpm. CAUTION When charging refrigerant system with the engine running;...

  • Page 863: Inspecting System For Leakage

    Inspecting System for Leakage After completing charging procedures, clean all joints and connections with a clean dry cloth. Using a refrigerant leak detecting device or soapy water, inspect system for leaks starting from the high-pressure side. NOTE: When the refrigerant circulation has been stopped the high-pressure will start to decrease and the low-pressure will start to increase until they are equalized.

  • Page 864: Troubleshooting

    TROUBLESHOOTING Refrigerant Pressure Check HDA6074L Figure 36 Open all doors and windows. Install manifold gauge set. Start engine and maintain engine speed at 1,800 - 2,000 rpm. Check high / low-pressure of refrigerant. High-pressure: 8 - 10 kg/cm (114 - 142 psi) Low-pressure: Approximately 1 kg/cm (14 psi) Possible Cause: Low Refrigerant Level...
  • Page 865 High-pressure: Approximately 20 - 25 kg/cm (285 - 355 psi) Low-pressure: Approximately 2.5 - 3.5 kg/cm (35 - 50 psi) Possible Cause: Air in system. Recover any remaining refrigerant. Vacuum out system. Recharge system. NOTE: If the system has been exposed to the air for a long period of time, replace the receiver dryer.
  • Page 866 High-pressure: Over 7 - 11 kg/cm (100 - 156 psi) Low-pressure: 4 - 6 kg/cm (57 - 85 psi) Possible Cause: Low refrigerant pressure due to poor compressor compression Inspect and replace compressor if necessary. Electrical System SP001687 Page 54...
  • Page 867 SP001688 ELECTRICAL SCHEMATIC (DX60R/DX80R) SP001688 Electrical Schematic (DX60R/DX80R) Edition 1 Electrical Schematic (DX60R/DX80R) SP001688 Page 1...
  • Page 868 MEMO Electrical Schematic (DX60R/DX80R) SP001688 Page 2...
  • Page 869 Table of Contents Electrical Schematic (DX60R/DX80R) Safety Precautions..........5 Applicable Models ..........5 DX60R/DX80R ............7 Electrical Schematic (DX60R/DX80R) SP001688 Page 3...
  • Page 870 MEMO Electrical Schematic (DX60R/DX80R) SP001688 Page 4...
  • Page 871 Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up Electrical Schematic (DX60R/DX80R) SP001688 Page 5...
  • Page 872 Electrical Schematic (DX60R/DX80R) SP001688 Page 6...
  • Page 873 0.5YR 0.5YW 0.5B BLOWER RELAY 36 37 38 WATER VALVE ASS’Y 15 14 21 22 (CN4) 11 12 18 19 (HI) 0.5LB 0.5LB HRS 26P (MID) 1.25B 0.5LY 0.5LY 0.5LW (LOW) 0.5LW FG013891 (CN3) Figure 1 Electrical Schematic (DX60R/DX80R) SP001688...
  • Page 875 Attachments...
  • Page 877 SP001642 BOOM AND ARM SP001642 Boom and Arm Edition 1 Boom and Arm SP001642 Page 1...
  • Page 878 MEMO Boom and Arm SP001642 Page 2...
  • Page 879 Table of Contents Boom and Arm Safety Precautions..........5 Applicable Models ..........5 Front Attachment Pin Specifications ....6 Front Attachment - Removal and Installation ..8 Arm Removal Procedure ..........8 Boom Removal Procedure ..........10 Installation ............11 Arm Installation Procedure..........
  • Page 880 MEMO Boom and Arm SP001642 Page 4...

  • Page 881: Boom And Arm

    Remember that ultimate safety is your own personal responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up Boom and Arm SP001642 Page 5...

  • Page 882: Front Attachment Pin Specifications

    NOTE: Some mounting pins must be drilled and tapped for lubrication fittings and piping, or may have other required specifications. Consult DOOSAN After Sales Service for information on wear tolerances and replacement limits for mounting pins. FG013470 Figure 1...
  • Page 883 Criteria Measuring Mark Size Tolerance Remedy Standard Clearance Clearance Limit Diameter Length Hole +0.29 -0.05 55 mm 357 mm 0.294 ~ Boom Foot Pin (2.17 in) (14.06 in) 0.364 +0.24 -0.07 -0.05 +0.20 Boom Cylinder 50 mm 224 mm 0.05 ~ 0.27 Head Pin (1.97 in) (8.82 in)

  • Page 884: Front Attachment - Removal And Installation

    FRONT ATTACHMENT - REMOVAL AND INSTALLATION DANGER DOOSAN warns any user, that the removal of the counterweight from the machine, front attachment or any other part, may affect the stability of the machine. This could cause unexpected movement, resulting in death or serious injuries.
  • Page 885 Park the excavator away from obstructions and all traffic on clear, flat, level ground. Extend the arm cylinder and crowd the arm into the boom. Partially retract the boom cylinder so that the boom is stretched out in front of the excavator, as low to the ground as possible, with the arm crowded under the boom.

  • Page 886: Boom Removal Procedure

    CAUTION To make sure that the polished surfaces of cylinder rod ends will not suffer accidental damage during disassembly or removal procedures, wrap exposed rod surfaces (especially those of boom cylinders) with a protective covering material. Immediately following disassembly and removal, cylinder rods should always be fully retracted.

  • Page 887: Installation

    Diagrams and Weights of Materials sections in the Operation and Maintenance Manual. Consult your dealer or DOOSAN After Sales Service for more information if you have any questions or require more information. Begin with the arm securely supported on blocking in front of the excavator.
  • Page 888 Boom and Arm SP001642 Page 12...
  • Page 889 SP001643 BUCKET SP001643 Bucket Edition 1 Bucket SP001643 Page 1...
  • Page 890 MEMO Bucket SP001643 Page 2...
  • Page 891 Table of Contents Bucket Safety Precautions..........5 Applicable Models ..........5 Bucket Tooth Replacement ........6 Bucket O-ring Replacement ......... 8 Bucket Attachment, Removal and Reversal ..9 Detaching the Bucket............9 Attaching the Bucket............. 10 Reversing the Bucket ............ 10 Bucket SP001643 Page 3...
  • Page 892 MEMO Bucket SP001643 Page 4...

  • Page 893: Safety Precautions

    Remember that ultimate safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up Bucket SP001643 Page 5...

  • Page 894: Bucket Tooth Replacement

    NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers buckets, refer to their specific instructions. Inspect locking pin assembly and replace it if the following...
  • Page 895 1/3T FG012221 Figure 4 HFO3043I Figure 5 Bucket SP001643 Page 7...

  • Page 896: Bucket O-Ring Replacement

    BUCKET O-RING REPLACEMENT WARNING Due to possibility of flying metal objects, always wear safety helmet, protective gloves and eye protection when changing pins. Inspect the bucket O-rings on a routine basis. If worn or damaged, replacement is necessary. FG010393 Figure 6 Roll the old O-ring (1, Figure 7) onto the boss (2) around the bucket pin (3).

  • Page 897: Bucket Attachment, Removal And Reversal

    Roll the new O-ring (1, Figure 9) into the O-ring groove. FG011411 Figure 9 BUCKET ATTACHMENT, REMOVAL AND REVERSAL Detaching the Bucket Park the excavator away from obstructions on clear, flat, level ground. Lower the bucket carefully to preassembled blocking on the ground.

  • Page 898: Attaching The Bucket

    Attaching the Bucket Carefully inspect all parts before reassembling the bucket linkage. Look for cracks or any other evidence of physical damage and replace any seal or O-ring that is not in like-new condition. Prelube linkage pins before assembly. Use an old cylinder rod, a long breaker bar or a similar, relatively thin diameter support bar for making the first (temporary) pin connection, between the bucket and arm.

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