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K1042957E Shop Manual
Copyright 2008 DOOSAN

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.

Shop Manual

K1042957E

Serial Number 50001 and Up

DX60R

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Summary of Contents for 50001

Page 1: ...ed 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...

Page 2: ......

Page 3: ...Product Label Instructions Trim Out The Label Along The Lines And Insert Into Pocket On The Binder Spine DX60R Serial Number 50001 and Up Pub No K1042957E Pub No K1042957E ...

Page 4: ......

Page 5: ...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 Center Joint Swivel SP001628 Cylinders SP001629 Swing Motor SP001630 Travel Motor SP001686 Main Control Valve SP001639 Main Pump SP001488 ...

Page 6: ...r 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 ...

Page 7: ...1Safety ...

Page 8: ......

Page 9: ...SP001614 Page 1 Track Excavator Safety SP001614 TRACK EXCAVATOR SAFETYSP001614 Track Excavator Safety Edition 1 ...

Page 10: ...SP001614 Track Excavator Safety Page 2 MEMO ...

Page 11: ...tor 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 13 General Hazard Information 13 Before Starting Engine 22 Machine Operation 26 Maintenance 33 Battery 44 Towing 46 Shipping and Transportation 47 Lifting With Sling 47 ...

Page 12: ...SP001614 Track Excavator Safety Page 4 MEMO ...

Page 13: ... 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 14: ...ge 1 11 4 Unauthorized Modifications on page 1 13 5 General Hazard Information on page 1 13 6 Before Starting Engine on page 1 22 7 Machine Operation on page 1 26 8 Maintenance on page 1 33 9 Battery on page 1 44 10 Towing on page 1 46 11 Shipping and Transportation on page 1 47 12 Lifting With Sling on page 1 47 DANGER Unsafe use of the excavator could lead to serious injury or death Operating pr...

Page 15: ...ns given in this manual can be applied only to intended uses of the machine If you use your machine for any unintended uses that are not specifically prohibited you must be sure that it is safe for any others 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 cou...

Page 16: ...ersonal injury or accidents Always observe safety precautions and follow recommended procedures CAUTION This word is used on safety messages and safety labels and indicates potential threat of a hazardous situation that if not avoided could result in minor or moderate injury It may also be used to alert against a generally unsafe practice WARNING This word is used on safety messages and safety lab...

Page 17: ...ance Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual are used you must be sure that you and others can do such procedures and actions safely and without damaging the machine If you are unsure about the safety of any procedures contact a DOOSAN distribu...

Page 18: ...pacity ratings that are printed at the end of this safety section are based on the machine being level on a firm supporting surface with hooks and slings attached in approved configuration Loads must be balanced and supported evenly Use tag lines to keep the load steady if wind conditions and large surface area are a problem Work crew hand signals individual tasks and safe procedures should all be...

Page 19: ... of the load Proper handling of the suspended load Tag lines on opposite sides of the load can be very helpful in keeping a suspended load secure if they are anchored safely to control points on the ground DANGER Unsafe use of the excavator while making rated lifts could cause serious potentially fatal injuries or extensive damage to the machine or nearby property Do not let anyone operate the mac...

Page 20: ...ore 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 of your individual operating environment please consult your local DOOSAN representative ...

Page 21: ... feeling well if you are taking medication that makes you feel sleepy if you have been drinking or if you are suffering from emotional problems These problems will interfere with your sense of judgment in emergencies and may cause accidents When working with another operator or with a person on work site traffic duty be sure that all personnel know the nature of the work and understand all hand si...

Page 22: ...e safety do not use the radio or music headphones when operating the machine There is a danger that this may lead to a serious accident When operating the machine do not put your hands or head out of the window When standing up from the operator s seat always place safety lock lever securely in the LOCK position If you accidentally touch the work equipment levers when they are not locked the machi...

Page 23: ...d root mean square acceleration to which the hands arms are subjected is less than 2 5 m s2 Whole body The weighted root mean square acceleration to which the whole body is subjected is less than 0 5 m s2 Measurements are obtained on a representative machine using measuring procedures as described in the following standard ISO 2631 1 ISO 5349 and SAE J1166 Recommendations for Limiting Vibrations 1...

Page 24: ...s or track shoes wipe it off immediately Always keep these parts clean Repair any damage and tighten any loose bolts Never jump on or off the machine In particular never get on or off a moving machine These actions may lead to serious injury When getting on or off the machine always face the machine and maintain three point contact both feet and one hand or one foot and both hands with the handrai...

Page 25: ...f the fuel nozzle in constant contact with the neck of the fuel filling nozzle to provide a ground Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured Precautions When Handling Fluids at High Temperature Immediately after operations are stopped the coolant engine oil and hydraulic oil are at highest temperatures and the radiator and hydraulic tan...

Page 26: ...trol levers are operated the clearance between the machine and the work equipment will change and this may lead to serious damage or personal injury If going between movable parts is necessary always position and secure the work equipment so it cannot move Fire Extinguisher and First Aid Kit As a precaution if any injury or fire should occur always do the following Be sure that fire extinguishers ...

Page 27: ...ject Protective Structure or window guards Never attempt to alter or modify any protective structure reinforcement system by drilling holes welding remounting or relocating fasteners Any serious impact or damage to the system requires a complete integrity reevaluation Reinstallation recertification and or replacement of the system may be necessary Contact your DOOSAN distributor for available safe...

Page 28: ... controls may enable the selected function to operate under force of gravity When performing maintenance on the pilot control system the hydraulic pressure in the system must be released as described in Handling of Accumulator in the Operation and Maintenance Manual The accumulator is charged with high pressure nitrogen gas so it is extremely dangerous if it is handled in the wrong way Always obse...

Page 29: ...lso be aware of open windows doors or ductwork where exhaust may be carried or blown by the wind exposing others to danger Emergency Exit This machine is equipped with a glass breaking tool It is to the left center of the cabin This tool can be used in case of an emergency situation which requires the breaking of glass to exit from the cabin Grip the handle firmly and use the sharp point to the gl...

Page 30: ...rk site Contact each utility and identify their locations Be careful not to damage or cut any of these lines Check the condition of the riverbed and the depth and flow of the water before operating in water or crossing a river NEVER work in water that is more than the permissible water depth Any object in vicinity of boom could represent a potential hazard or cause the operator to react suddenly a...

Page 31: ...per and other flammable materials accumulated in the engine compartment and around the battery They could cause a fire Remove any dirt from the window glass mirrors handrails and steps Do not leave tools or spare parts laying around in the operator s cabin The vibration of the machine when traveling or during operations may cause them to fall and damage or break the control levers or switches They...

Page 32: ...e engine if there is any indication that maintenance or service work is in progress or if a warning tag is attached to controls in the cabin A machine that has not been used recently or is being operated in extremely cold temperatures could require a warm up or maintenance service before start up Check gauges and monitor displays for normal operation before starting the engine Listen for unusual n...

Page 33: ...mediately If the machine is used without repairing the problems it may lead to unexpected injury or failure Clear all personnel from directly around machine and from the area Clear all obstacles from the machine s path Beware of hazards Be sure that all windows are clean Secure the doors and the windows in the open position or in the shut position Adjust the rearview mirrors for best visibility cl...

Page 34: ...urning radius or direction of travel Be sure to observe the above precautions even if a travel alarm or mirrors are installed Travel Precautions Never turn the starting switch to the O OFF position when traveling It is dangerous if the engine stops while the machine is traveling It will be impossible to operate the steering Attachment control levers should not be operated while traveling Do not ch...

Page 35: ...nger of serious injury Traveling on slopes could result in the machine tipping over or slipping On hills banks or slopes carry the bucket approximately 20 30 cm 8 12 in above the ground In case of an emergency quickly lower the bucket to the ground to help stop the machine Do not travel on grass fallen leaves or wet steel plates Even slight slopes may cause the machine to slip to the side so trave...

Page 36: ...s or other inadequate supports when work is being done Block tracks fore and aft to prevent any movement When using the machine to prevent accidents caused by damage to the work equipment and overturning because of an excessive load do not use the machine in excess of its ability in terms of the maximum load and stability determined by the structure of the machine When working at the edge of an ex...

Page 37: ...e the machine at a safe speed when working in confined spaces indoors or in crowded areas Do not pass the bucket over the heads of workers or over the operator s cabin of dump truck Avoid High voltage Cables Serious injury or death can result from contact or proximity to high voltage electrical lines The bucket does not have to make physical contact with power lines for current to be transmitted U...

Page 38: ...ures Reducing work cycle rate and workload may be necessary When the temperature rises frozen road surfaces become soft and machine travel becomes unstable In cold weather do not touch metal surfaces with your bare hands If you touch a metal surface in extremely cold weather your skin may freeze to the metal surface Operations on Slopes When working on slopes there is a danger that the machine may...

Page 39: ...ort saddle There should be no possibility of unintended or accidental movement When parking on public roads provide fences signs flags or lights and put up any other necessary signs to ensure that passing traffic can see the machine clearly Park the machine so the machine flags and fences do not obstruct traffic After the front attachment has been lowered to an overnight storage position and all s...

Page 40: ...l to warn people nearby Keep windows mirrors and headlights clean and good repair at all times Slow down when visibility is poor because of dust heavy rain fog or other conditions Never Let Anyone Ride on Attachment Never let anyone ride on any work attachment such as the bucket crusher grapple or clamshell grab bucket There is a danger of the person falling and suffering serious injury Figure 27 ...

Page 41: ...nger that you may get dirt or mud in your eyes or that you may slip and injure yourself When washing the machine do the following Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your skin or having mu...

Page 42: ...g fuel oil battery electrolyte or window washing fluid always use lighting with antiexplosion specifications If such lighting equipment is not used there is a danger of an explosion If work is carried out in dark places without using lighting it may lead to injury so always use proper lighting Even if the place is dark never use a lighter or flame instead of lighting There is a danger of fire Ther...

Page 43: ... smoke in battery charging areas or in areas the contain flammable material Clean all electrical connections and tighten all electrical connections Check the electrical wires daily for wires that are loose of frayed Tighten all lose electrical wires before you operate the machine Repair all frayed electrical wires before you operate the machine Remove all flammable materials before they accumulate...

Page 44: ... to cool before you drain the cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only after the engine has been stopped Make sure that the hydraulic tank filter plug is cool before you remove it with your bare hand Remove the hydraulic tank filter plug slowly to relieve pressure Reliev...

Page 45: ...catching fire To avoid this never subject these places to heat Do not weld on pipes or on tubes that contain flammable fluids Do not flame cut on pipes or on tubes that contain flammable fluids Before you weld on pipes or on tubes or before you flame cut on pipes or on tubes clean the pipes or tubes thoroughly with a nonflammable solvent If heat is applied directly to rubber hoses or piping under ...

Page 46: ... 8 Connect the battery terminal cables 9 Reassemble the cover over the battery 10 Close the door of the battery cover Warning for Counterweight and Front Attachment Removal FG012417 Figure 35 FG012418 1 Figure 36 FG012419 Figure 37 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 ca...

Page 47: ...point contact both feet and one hand or both hands and one foot to support yourself securely If the job requires it wear protective clothing To prevent injury from slipping or falling when working on the hood or covers never use any area except the area equipped with nonslip pads Lock Inspection Covers When carrying out maintenance with the inspection cover open lock the cover securely in position...

Page 48: ...ssemble the track adjuster or attempt to remove grease fitting or valve assembly Keep your face and body away from the valve Refer to the track adjustment procedure in the Operator and Maintenance Manual or Shop Manual Supports and Blocks for Work Equipment Do not allow weight or equipment loads to remain suspended Lower everything to the ground before leaving the operator s seat Do not use hollow...

Page 49: ...o prevent vibration rubbing against other parts and excessive heat during operation If any of the following conditions are found replace the part Damage or leakage from hose end Wear damage cutting of covering or exposure of strengthening wire layer Cover portion is swollen in places There is twisting or crushing at movable parts of hose Foreign material is embedded in the covering Hose end is def...

Page 50: ...move two screws and cover 2 6 Rotate the cabin crank 3 with a M27 wrench to raise cabin FG012858 Figure 44 FG012420 3 2 1 Figure 45 WARNING 1 Only use a hand tool to raise cabin Do not use an impact wrench 2 This operation should be done on firm level ground 3 Make sure there is no one inside cabin when doing this operation 4 When raising cabin do not allow anyone or any portion of their body unde...

Page 51: ... secured before operating Do not replace tilting mechanism components with cabin tilted This may result in machine damage or personal injuries FG012422 Figure 48 WARNING 1 Make sure there is nothing between cabin and main frame This includes tools used for servicing machine or used to raise cabin 2 Watch cabin until it is resting on main frame 3 After releasing safety bar immediately lower cabin D...

Page 52: ...ities of water and see a doctor at once If you accidentally drink battery electrolyte drink a large quantity of water or milk raw egg or vegetable oil Call a doctor or poison prevention center immediately When cleaning the top surface of the battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely If the battery ...

Page 53: ...rical switches on the battery charger or boost starting equipment When boost starting from another machine or vehicle do not allow the two machines to touch Wear safety glasses or goggles while required battery connections are made Connect positive cable first when installing cables and disconnect the negative cable first when removing them The final cable connection at the metal frame of the mach...

Page 54: ...left and right hooks and secure in position If the engine on the problem machine will not start or there is a failure in the brake system always contact your DOOSAN distributor Never go between the towing machine and the towed machine during the towing operation It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no place where the slope is gradua...

Page 55: ...for information on partial disassembly Refer to the Transportation and Shipping section of this Operation and Maintenance Manual for information on loading unloading and towing LIFTING WITH SLING 1 Refer to Specification section of this manual for information on weight and dimensions 2 Use properly rated cables and slings for lifting 3 Position machine for a level lift 4 Lifting cables should have...

Page 56: ...SP001614 Track Excavator Safety Page 48 ...

Page 57: ...1Specifications ...

Page 58: ......

Page 59: ...SP001615 Page 1 Specification for DX60R SP001615 SPECIFICATION FOR DX60RSP001615 Specification for DX60R Edition 1 ...

Page 60: ...SP001615 Specification for DX60R Page 2 MEMO ...

Page 61: ...tions 8 Overall Dimensions 10 Working Range 12 Standard Specifications 14 Engine Performance Curves 15 Approximate Weight of Workload Materials 18 Performance Tests 20 Excavator Performance Standards 21 Test Conditions 21 Travel Speed and Travel Motor Balance Steering Deviation Tests 21 Swing Speed and Deceleration Force Test 23 Cylinder Performance Tests 24 ...

Page 62: ...SP001615 Specification for DX60R Page 4 MEMO ...

Page 63: ... 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 64: ...SP001615 Specification for DX60R Page 6 ...

Page 65: ...ESCRIPTION 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 ...

Page 66: ...SP001615 Specification for DX60R Page 8 COMPONENT LOCATIONS Figure 1 21 22 24 25 26 23 27 28 29 30 1 2 6 3 4 5 13 14 15 8 9 7 12 11 10 17 16 18 19 20 FG012434 ...

Page 67: ...er 8 Center Joint 9 Control Valves 10 Swing Bracket 11 Boom Cylinder 12 Boom 13 Arm Cylinder 14 Arm 15 Bucket Cylinder 16 Push Link 17 Guide Link 18 Bucket 19 Side Cutter 20 Tooth Point 21 Blade 22 Blade Cylinder 23 Track Guide 24 Idler 25 Track AdujsterIdler 26 Battery 27 Upper Roller 28 Lower Roller 29 Travel Motor 30 Track Link and Shoe Reference Number Description ...

Page 68: ...SP001615 Specification for DX60R Page 10 OVERALL DIMENSIONS FG012609 5 0 7 0 U T J K A B D C M N I H P Q R L F G E S O Figure 2 ...

Page 69: ...18 4 B 1 269 mm 4 2 C 1 102 mm 3 7 D 4 334 mm 14 3 E 1 939 mm 6 4 F 440 mm 1 5 G 410 mm 1 4 H 1 791 mm 5 10 I 1 990 mm 6 6 J 2 538 mm 8 4 K 3 060 mm 10 0 L 640 mm 2 1 M 1 904 mm 6 3 N 1 030 mm 3 5 O 927 mm 3 0 P 2 546 mm 8 4 Q 319 mm 1 1 R 584 mm 1 11 S 400 mm 1 4 T 1 580 mm 5 2 U 1 980 mm 6 6 ...

Page 70: ... L digging reach depends on the stability and support provided by ground conditions 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 G L K E I F H D J G C A FG013195 B L Figure 3 ...

Page 71: ...ging Depth 3 725 mm 12 3 4 145 mm 13 7 D Max Loading Height 3 940 mm 12 11 4 125 mm 13 6 E Min Swing Radius 2 415 mm 7 11 2 500 mm 8 2 F Max Digging Height 5 685 mm 18 8 5 855 mm 19 2 G Max Bucket Pin Height 4 830 mm 15 10 5 010 mm 16 5 H Max Vertical Wall Depth 3 095 mm 10 2 3 165 mm 10 5 I Max Radius Vertical 3 870 mm 12 8 4 415 mm 14 6 J Max Depth to 8 ft Line 3 320 mm 10 11 3 770 mm 12 4 K Min...

Page 72: ... 664 mm 18 7 Height 2 560 mm 8 5 2 560 mm 8 5 Height Boom 1 940 mm 6 4 2 188 mm 7 2 Width 1 980 mm 6 6 1 980 mm 6 6 Performance Max diggin g force ISO Bucket 39 9 KN 39 9 KN Arm 26 KN 22 6 KN Traveling speed 1 speed 2 07 km h 2 speed 3 9 km h Swing speed 9 58 rpm Drawbar pull 5 300 kg Hydraulic pump Type Variable displacement axial piston pump Max flow rate 49 3 x 2 l min 35 6 l min Gear pump 9 9 ...

Page 73: ...23 200 20 175 18 150 15 125 13 100 10 75 8 320 235 5 7 4 2 0 600 500 400 300 ps 800 1 000 1 200 1 400 1 600 1 800 2 000 2 200 2 400 2 600 55 75 50 68 45 61 40 54 35 48 30 41 25 34 20 27 15 20 10 14 300 221 280 206 260 191 240 177 220 162 200 147 kgf m N m g PSh B S F C Torque g kWh KW Output Exhaust Gas Temp C Smoke FG013211 Figure 4 ...

Page 74: ...ernorbility Governor Type Electric governor ECO Temporary Max 12 Load 100 0 Permanent Max 7 Recovery Time sec Max 6 Stability min 1 Max 22 Gradients Longitudinal deg 35 30 Intermitted continuous Lateral deg 35 30 Firing Order 1 3 4 2 1 Order from F W Direction of Rotation Counterclockwise Viewed from F W Engine Dry Weight kg Approx 270 Fuel Injection Timing deg FIR 3 0 5 0 5 FIT 14 0 B T D C Fuel ...

Page 75: ...al maximum restrictions 2 9 kPa 300 mmAq Breather System Closed type Muffler ø 170 460 To be set by the technical bulletin 071001 Technical Bullete in 07_105 Intake_Exhaust pressure matching pdf Intial maximum restrictions 12 7 kPa 1 300 mmAq Starting System Starter 12V 3 0kW Battery 130E41 Starting Aid Air heater 500W Generator 12V 6A Engine Color Black Applied Regulation EPA Intermediate Tier 4 ...

Page 76: ...R DENSITY 2 000 kg m3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry size 449 kg m3 756 lb yd3 Coal bituminous slack piled 801 kg m3 1 350 lb yd3 Coal bituminous r of m piled 881 kg m3 1 485 lb yd3 Coal anthracite 897 kg m3 1 512 lb yd3 Clay DRY in broken lumps 1 009 kg m3 1 701 lb yd3 Clay DAMP natural bed 1 746 kg m3 2 943 lb yd3 Ceme...

Page 77: ... crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1 282 kg m3 2 160 lb yd3 Salt 929 kg m3 1 566 lb yd3 Snow light density 529 kg m3 891 lb yd3 Sand DRY loose 1 522 kg m3 2 565 lb yd3 Sand WET packed 1 922 kg m3 3 240 lb yd3 Shale broken 1 362 kg m3 2 295 lb yd3 Sulfur broken 529 kg m3 1 620 lb yd3 MATERIAL LOW WEIGHT OR DENSITY 1 100 kg m3 1 850 LB YD3 OR LES...

Page 78: ...mp sec 2 5 0 3 Crowd sec 2 2 0 3 Bucket Dump sec 3 6 0 3 Crowd sec 2 3 0 3 Dozer Up sec 2 4 0 3 Down sec 3 1 0 3 Boom Swing L R sec 7 7 0 5 R L sec 8 8 0 5 Swing 3 Revolutions sec 19 2 1 0 Jack up Speed 3 Turns 1 speed sec 28 4 1 5 2 speed sec 14 8 1 0 Travel Speed 20 m 66 ft 1 speed sec 34 9 2 0 2 speed sec 18 6 1 5 Travel Deviation 20 m 66 ft 1 speed mm in 300 11 8 2 speed mm in 300 11 8 ...

Page 79: ...ommended applicable maintenance and adjustment service should be completed before testing 3 Hydraulic fluid and engine oil should be of appropriate viscosity for ambient weather Warm up hydraulic oil to standard operating temperature between 45 55 C 112 135 F 4 Run all tests with the engine speed control set to maximum rpm 5 Repeat tests with engine control settings at maximum rpm Travel speed tes...

Page 80: ... the turntable 180 Both tests should be repeated three times Average all results to obtain a final value Travel Deviation To check steering deviation travel motor balance use a long tape or rope or the edge of an undeviating straight road curb or other marker to verify side to side travel motor uniformity Deviation distance should always be measured at the 20 m 65 7 1 2 finish line Repeat the test...

Page 81: ...e boom arm and bucket in the same position as for the swing speed test rotate the turntable so the boom is evenly centered between the side frames pointing straight ahead Locate the 90 reference point perpendicular to the boom Mark the turntable and undercarriage with paint at the 90 point Make several attempts to rotate the turntable exactly 90 starting from the boom straight ahead position Engag...

Page 82: ... the arm cylinder fully retracted Test movement in both directions several times between the crowd and dump positions and average the results of both tests Bucket Cylinder Test Start with the boom up and the teeth of the bucket hanging vertically 500 mm 1 1 2 2 above the ground Dump and crowd the bucket several times and average results Boom Arm Bucket Dozer B Swing Quantity EA 1 1 1 1 1 Bore ø 10...

Page 83: ...Shut down engine and measure cylinder drop after 5 minutes Bucket cylinder should not show more than 40 mm 1 57 change while the arm and boom cylinders should not fall more than 10 mm 0 39 Travel Motor Jack up Test Test travel motor operation on each side by painting or chalking a mark on one crawler shoe with a corresponding mark on the travel frame Use the attachment to jack up one side of the m...

Page 84: ...SP001615 Specification for DX60R Page 26 ...

Page 85: ...1General Maintenance ...

Page 86: ......

Page 87: ...SP000016 Page 1 General Maintenance Procedures SP000016 GENERAL MAINTENANCE PROCEDURES SP000016 General Maintenance Procedures Edition 1 ...

Page 88: ...SP000016 General Maintenance Procedures Page 2 MEMO ...

Page 89: ...elding 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 10 Oil Leakage Precautions 11 Cleaning and Inspection 12 General Guidelines 12 Bearing Inspection 13 ...

Page 90: ...SP000016 General Maintenance Procedures Page 4 MEMO ...

Page 91: ...TION 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 Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES ...

Page 92: ...ese types of steel are performed with the proper procedures and equipment 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 It is possible...

Page 93: ...ocedures are being performed near cylinder rods operator s cabin window areas or any other assemblies that could be damaged by weld spatters use adequate shielding in front of them 5 During equipment setup always attach ground cables directly to the area or component being welded to prevent arcing through bearings bushings or spacers 6 Always use correct welding rods for the type of weld being per...

Page 94: ...d Replacement of any hydraulic system component could require thorough cleaning flushing and some amount of prefilling with fresh clean oil if the protective seal on replacement parts has obviously been broken or if seal integrity may have been compromised When protective seals are removed before installation and reassembly inspect all replacement parts carefully before they are installed If the r...

Page 95: ...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 For example the reservoir fill cap and neck area hoses that have to be disassembled and the covers and external surfaces of filter canisters should all be cleaned before disassembl...

Page 96: ... hydraulic circuit may be imminent or have already occurred Open the drain plugs on the main pump casings and check and compare drain oil in the pumps Look for evidence of grit or metallic particles Vibration or unusual noise during operation could be an indication of air leaking into the circuit Refer to the appropriate Troubleshooting section for component or unit for procedures or it may be evi...

Page 97: ...sidue solvent and thoroughly clean exterior surfaces of assemblies before any part of the circuit is opened or disassembled NOTE It s just as important to clean the cap and reservoir top before routine fluid changes or quick checks as it is before major repairs Accumulated dirt attracts moisture oil and other fluids and more dirt Keep dismantled parts covered during disassembly Use clean caps plug...

Page 98: ...full of fine dust are especially hazardous Clogging of valve spools or external piping especially pilot circuit piping can gradually diminish or suddenly put a stop to normal hydraulic function You can prevent having to make these types of repairs by following recommended assembly procedures 1 Use new O rings and oil seals whenever hydraulic assemblies are rebuilt 2 Prepare joint surfaces before a...

Page 99: ...void spinning bearings that are not lubricated DO NOT SPIN BEARINGS WHEN DRYING bearings may be rotated slowly by hand to facilitate drying process 3 Carefully inspect all bearing rollers cages and cups for wear chipping or nicks to determine condition Do not replace a bearing cone or cup individually without replacing mating cup or cone at the same time After inspection dip bearings in lightweigh...

Page 100: ...aces of cast parts and machined surfaces for scratches wear grooves and dirt Remove any scratches and burrs with crocus cloth Remove foreign material Replace any parts that are deeply grooved or scratched which would affect their operation Bearing Inspection The condition of the bearings are vital to the smooth and efficient operation of the machinery When any component containing bearings is disa...

Page 101: ...conditions that indicate the bearing has been turning in its housing or on its shaft If available use magna flux or similar process for checking for cracks that are not visible The following illustrations will aid in identifying and diagnosing some of the bearing related problems NOTE The illustrations will only show tapered roller bearings but the principles of identifying diagnosing and remedyin...

Page 102: ...erheating lubricant failure or overload Replace bearing check seals and check for proper lubrication 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 Figure 4 Figure 5 Figure 6 ...

Page 103: ...s check seals and check for proper lubrication Misalignment Outer race misalignment because of foreign object Clean related parts and replace bearing Make sure races are properly seated Indentations Surface depressions on race and rollers caused by hard particles of foreign materials Clean all parts and housings check seals and replace bearings if rough or noisy Figure 7 Figure 8 Figure 9 ...

Page 104: ...s 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 Cage Wear Wear around outside diameter of cage and roller pockets caused by abrasive material and inefficient lubrication Replace bearings check seals Figure 10 Figure 11 Figure 12 ...

Page 105: ...Cracked Inner Race Race cracked because of improper fit cocking or poor bearing seat Replace all parts and housings check seals and bearings and replace if leaking Smears Smearing of metal because of slippage caused by poor fitting lubrication overheating overloads or handling damage Replace bearings clean related parts and check for proper fit and lubrication Replace shaft if damaged Figure 13 Fi...

Page 106: ...r loss of temper on races or rollers a simple file test may be made A file drawn over a tempered part will grab and cut metal whereas a file drawn over a hard part will glide readily with no metal cutting Replace bearing if overheating damage is indicated Check seals and other related parts for damage Stain Discoloration Discoloration can range from light brown to black caused by incorrect lubrica...

Page 107: ...SP000813 Page 1 Standard Torques SP000813 STANDARD TORQUESSP000813 Standard Torques Edition 1 ...

Page 108: ...SP000813 Standard Torques Page 2 MEMO ...

Page 109: ...or 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 10 Torque Wrench Extension Tools 11 Torque Multiplication 11 Other Uses for Torque Wrench Extension Tools 12 Tightening Torque Specifications Metric 13 ...

Page 110: ...SP000813 Standard Torques Page 4 MEMO ...

Page 111: ... 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 Remember that ultimate safety is your own personal responsibility MODEL SERIAL NUMBER RANGE ALL MODELS ALL RANGES ...

Page 112: ...12 00 86 79 17 00 122 96 20 00 144 66 M14 x 1 5 4 10 29 65 4 30 31 10 6 60 47 73 5 70 41 22 8 30 60 03 7 50 54 24 11 10 80 28 12 50 90 41 13 00 94 02 18 50 133 81 22 00 159 12 M16 x Std 5 60 40 50 6 00 43 39 9 00 65 09 8 00 57 86 11 50 83 17 10 50 75 94 15 50 112 11 17 90 129 47 18 50 133 81 26 00 188 05 31 00 224 22 M16 x 1 5 6 20 44 84 6 50 47 01 9 70 70 16 8 60 62 20 12 50 90 41 11 30 81 73 17 ...

Page 113: ...sed 0 70 When Molykote white lead or similar mixtures are used as lubricants 0 75 When Parkerized bolts or nuts are used 0 85 When cadmium plated bolts or nuts and zinc bolts w waxed zinc nuts are used 0 90 When hardened surfaces are used under the nut or bolt head NOTE When reusing bolts and nuts in service use minimum torque values Type S A E Grade Description Bolt Head Marking 1 1 OR 2 WILL HAV...

Page 114: ...oot Pounds ft lb Newton Meter Nm Foot Pounds ft lb Newton Meter Nm 1 4 20 6 8 9 12 1 4 28 7 9 11 15 5 16 18 13 18 18 24 5 16 24 15 20 21 28 3 8 16 24 33 34 46 3 8 24 27 37 38 52 7 16 14 38 52 54 73 7 16 20 42 57 60 81 1 2 13 58 79 82 111 1 2 20 65 88 90 122 9 16 12 84 114 120 163 9 16 18 93 126 132 179 5 8 11 115 156 165 224 5 8 18 130 176 185 251 3 4 10 205 278 290 393 3 4 16 240 312 320 434 7 8 ...

Page 115: ...ues shown below also apply to the following 1 Phosphate coated bolts used in tapped holes in steel or gray iron 2 Phosphate coated bolts used with phosphate coated prevailing torque nuts nuts with distorted threads or plastic inserts 3 Phosphate coated bolts used with copper plated weld nuts Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required to...

Page 116: ...ange on end of hydraulic tube or hose fitting NOTE Values stated in chart are for Standard Pressure Series Code 61 Split Flanges Clamp Type And Size Torque Radiator Air Cleaner Boots Etc Hydraulic System Kilogram Meter kg m Inch Pounds in lb Kilogram Meter kg m Inch Pounds in lb T Bolt Any Diameter 0 68 0 72 59 63 Worm Drive Under 44 mm 1 3 4 in Open Diameter 0 2 0 3 20 30 0 5 0 6 40 50 Worm Drive...

Page 117: ...or situations if the right extension tool is used or fabricated Torque Multiplication A wrench extension tool can be used to increase the tightening force on a high capacity nut or bolt For example doubling the distance between the bolt and the back handle end of the torque wrench doubles the tightening force on the bolt It also halves the indicated reading on the scale or dial of the torque wrenc...

Page 118: ...n a fastener For example a torque wrench and extension can be used to measure adjustment tightness of a linkage or assembly Specially fabricated extensions can be used to make very precise checks of the force required to engage or disengage a clutch mechanism release a spring applied brake assembly or take up free play in most any movable linkage Once the value of the adjustment force is establish...

Page 119: ...y compound 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 IMPORTA...

Page 120: ...C 500 F Remove HOT 210 Product Application Color Removal Required Setup 545 No filler nonclog formula for high pressure hydraulic systems Over application will not restrict or foul system components Purple Hand tools 4 Hours or 1 2 hour with Locquic T Primer 656 Solvent resistant higher viscosity tapered thread sealer White Hand tools 4 Hours or 1 2 hour with Locquic T Primer Product Application C...

Page 121: ... cold temperature applications 620 For high temperatures to 232 C 450 F Green Same as 609 above 680 For high strength bonds and tight clearance gaps to 0 00008 mm 0 002 Green Same as 609 above Product Application Color Notes 380 Black Max instant adhesive for shock and vibration resistant bonds Black May take 120 hours to reach full cure strength 454 Adhesive for porous surfaces Clear Full strengt...

Page 122: ...SP000813 Standard Torques Page 16 ...

Page 123: ...1Upper Structure ...

Page 124: ......

Page 125: ...SP001623 Page 1 Cabin SP001623 CABIN SP001623 Cabin Edition 1 ...

Page 126: ...SP001623 Cabin Page 2 MEMO ...

Page 127: ...SP001623 Page 3 Cabin Table of Contents Cabin Safety Precautions 5 Applicable Models 5 Removal 6 Installation 10 ...

Page 128: ...SP001623 Cabin Page 4 MEMO ...

Page 129: ... 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up ...

Page 130: ...ess B Left stand harness C Right stand harness D Harness passing next to the air conditioner box NOTE Control console wiring harnesses and hydraulic piping lines that pass through the floor of the cabin do not need to be disassembled NOTE If unit is equipped with a cabin protective structure for forestry or hazardous working conditions it must be removed CAUTION Avoid disassembling cabin if there ...

Page 131: ...e careful about hydraulic oil leak 13 Remove seven M8 bolts Then open side cover of main frame Figure 3 Remove front pivot bracket four bolts M12 and washers outside of cabin Figure 4 Remove two M16 bolts and washers to split tilting lever from main frame Figure 5 14 Remove floor mat FG013471 Figure 2 Figure 3 FG013818 FG013823 Figure 4 Figure 5 FG013822 ...

Page 132: ...gure 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 16 Disconnect washer hose located at floor plate Figure 6 FG013820 A Figure 7 FG013821 B Figure 8 FG010290 C E FG011063 Figure 9 ...

Page 133: ... Figure 12 NOTE The weight of cabin is about 480 kg 1 058 2 lb 19 Lift cabin approximately 25 50 mm 1 2 above deck Check that all electrical connections have been disconnected and all other items unbolted 20 Continue lifting with the assist crane to remove the cabin Lower the cabin to a prepared safe blocking support D FG011065 Figure 10 FG013819 Figure 11 FG013824 Figure 12 ...

Page 134: ... 1 058 2 lb 2 Lower cabin into position on floor 3 Install six bolts M10 and washer a nut M10 two nuts M16 and washers Figure 14 Install two M16 bolts and washers to split tilting lever from main frame Figure 14 Install front pivot bracket 2 four bolts M12 and washers outside of cabin Figure 15 FG013819 Figure 13 FG013822 Figure 14 FG013823 Figure 15 ...

Page 135: ...ss of stand of both ends and the harness passing next to the air conditioner box in that order A D Figure 16 Figure 19 6 Assemble the air conditioner filter and air conditioner box cover 7 Connect washer hose located at floor plate FG013820 A Figure 16 Figure 17 FG013821 B FG010290 C Figure 18 D FG011065 Figure 19 ...

Page 136: ...ure 21 9 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 10 Install floor mat 11 Connect negative battery cable leading to frame from battery FG013471 Figure 20 Figure 21 FG013818 ...

Page 137: ...SP001624 Page 1 Swing Bearing SP001624 SWING BEARING SP001624 Swing Bearing Edition 1 ...

Page 138: ...SP001624 Swing Bearing Page 2 MEMO ...

Page 139: ...tents 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 ...

Page 140: ...SP001624 Swing Bearing Page 4 MEMO ...

Page 141: ...ow 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 142: ... points 90 apart around the circumference of the bearing Figure 1 Record and keep all measurements Play in the bearing should increase minimally from one inspection to the next Eventually however as the bearing begins to approach the limit of its service life clearance increases become much more pronounced and the actual measured play in the bearing could exceed twice the value that was measured w...

Page 143: ...s transferred to the pinion by planetary gears connected to gears on the inner ring which is fixed in the undercarriage Ball bearings turn the outer ring Rebuilding Swing Bearing 1 Remove tip of tapered pin 1 Figure 3 using grinder and tap lightly to remove debris 2 Remove plug 1 Figure 4 using a M10 x 1 25 bolt 2 Figure 2 Reference Number Description 1 Ball 2 Seal A 3 Retainer 4 Outer Ring 5 Inne...

Page 144: ... and check that inner ring can move freely See Figure 5 if not replace seal 3 Figure 4 4 Turn inner ring and use magnet bar 1 Figure 6 to remove steel balls 2 5 Turn inner ring and use wire 1 Figure 7 to remove retainers 2 Figure 5 Figure 6 Figure 7 ...

Page 145: ...1Lower Structure and Chassis ...

Page 146: ......

Page 147: ...SP001625 Page 1 Track Assembly SP001625 TRACK ASSEMBLY SP001625 Track Assembly Edition 1 ...

Page 148: ...SP001625 Track Assembly Page 2 MEMO ...

Page 149: ...9 Steel Tracks 11 Track Frame Spring 12 Idler 13 Steel Tracks 13 Spring Specifications 14 Lower Roller 15 Steel Track 15 Rubber Track 16 Upper Roller 17 Sprocket 18 Track Removal and Installation 19 Track Removal 19 Track Installation 20 Replacement of Rubber Tracks with Steel Tracks 21 Replacement of Steel Tracks with Rubber Tracks 22 Idler 23 Disassembly 24 Reassembly 24 Track Tension Adjusting ...

Page 150: ...Track Assembly Page 4 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 ...

Page 151: ...low 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 152: ...SP001625 Track Assembly Page 6 TRACKS Specification and Construction Steel Tracks Track Frame Figure 1 FG013225 Track Frame Lower Roller Track Adjuster Figure 2 ...

Page 153: ...y Clean off tracks before checking clearance 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 Warm up the engine to prevent stalls travel the exc...

Page 154: ...oosen valve slowly a maximum of 1 to turns 2 When track tension is correct tighten track tension grease valve to 59 88 Nm 6 9 kg m 43 65 ft lb 3 Recheck tension by moving track forward and backward 4 Recheck tension and adjust as necessary Figure 4 Figure 5 WARNING The track adjusting mechanism is under very high pressure NEVER release pressure too suddenly The track tension grease valve should ne...

Page 155: ...o maintenance or renewal is possible Compare the values in the tables with dimensions and profiles shown in the following figures Rubber Track Features The amount of friction of rubber track sets limit of use However it is subject to change depending upon work condition and environment CAUTION Refer to the Welding Precautions and Guidelines information in General Maintenance Procedures section for...

Page 156: ...Figure 10 Item DX60R Distance Between Centers of Tracks 5 365 10 mm 211 22 0 39 in Scale Cord Rigid 1 000 0 kg 2 200 lb Scale Cord Number of Coils 44 4 Range of Temperature for Use 25 C 55 C 13 131 F Width x Pitch 400 x 72 5 mm 15 74 x 2 85 in ...

Page 157: ...Remarks 1 Link Pitch 135 mm 5 32 in 137 mm 5 4 in 2 Link Height 70 0 mm 2 75 in 67 5 mm 2 66 in Build up or replace 3 Track Height 14 1 mm 0 55 0 04 in 9 0 mm 0 35 in Build up or replace 4 Pin Clearance 0 15 mm 0 01 in 2 0 mm 0 08 in Replace 5 Bushing Thickness 39 mm 1 53 in 37 6 mm 1 48 in Replace ...

Page 158: ... between upper and lower sides of idler guide Standards Limits Build up or replace Track frame 69 0 mm 2 71 in 74 0 mm 2 91 in Idler frame 67 0 mm 2 64 in 62 0 mm 2 44 in 3 Gap between left and right of idler guide Idler support 166 0 mm 6 54 in 171 0 mm 6 73 in Build up or replace Track frame 170 0 5 mm 6 69 0 02 in 165 0 mm 6 5 in 4 Track spring Standards Free length Installed load Installed len...

Page 159: ...n 4 Flange Width 46 6 mm 1 83 in 5 Thread width 25 6 mm 1 01 in 31 1 mm 1 22 in Repair 6 Shaft Bushing Clearance Standard dimension Tolerance Standard Clearance Allowable wear limit Shaft Hole 34 mm 1 34 in 33 95 34 32 Max 0 39 Undefinable 33 925 34 21 Min 0 26 7 Body Bushing Press Fit Standard dimension Tolerance Standard Press Fit Allowable wear limit Bushing Hole 38 mm 1 49 in 38 103 38 05 Max ...

Page 160: ...Spring Constant 75 5 kgf mm 4 227 lb in Set Load 2 600 0 kg 5 730 lb Compressive Load 5 780 0 kg 12 740 lb Free Length LO 303 6 mm 11 95 in Minimum Closed Length 227 0 mm 8 94 in Outside Diameter 128 0 mm 5 04 in Mean Diameter 102 0 mm 4 02 in Inside Diameter 76 0 mm 3 00 in Wire Diameter 26 0 mm 1 02 in Set Length 269 0 mm 10 6 in ...

Page 161: ...m 5 5 in 4 Diameter of Link 110 mm 4 33 in 102 mm 4 02 in Repair 5 Shaft Bushing Clearance Standard dimension Tolerance Standard Clearance Allowable wear limit Shaft Hole 35 mm 1 38 in 34 95 35 36 Max 0 44 Undefinable 34 925 35 22 Min 0 27 6 Body Bushing Press Fit Standard dimension Tolerance Standard Fit Allowable wear limit Bushing Hole 41 15 mm 1 6 in 41 15 41 18 Max 0 15 Nonoccurrence 41 1 41 ...

Page 162: ...1 in 4 Diameter of Link 100 mm 3 93 in 92 mm 3 62 in Repair 5 Shaft Bushing Clearance Standard dimension Tolerance Standard Clearance Allowable wear limit Shaft Hole 32 mm 1 26 in 31 95 32 33 Max 0 37 Undefinable 31 925 32 28 Min 0 20 6 Body Bushing Press Fit Standard dimension Tolerance Standard Fit Allowable wear limit Bushing Hole 36 mm 1 41 in 36 15 36 05 Max 0 13 Nonoccurrence 36 10 36 02 Min...

Page 163: ... in 4 Diameter of Link 100 mm 3 93 in 92 mm 3 62 in Repair 5 Shaft Bushing Clearance Standard dimension Tolerance Standard Clearance Allowable wear limit Shaft Hole 32 mm 1 26 in 31 95 32 33 Max 0 37 Undefinable 31 925 32 28 Min 0 20 6 Body Bushing Press Fit Standard dimension Tolerance Standard Fit Allowable wear limit Bushing Hole 36 mm 1 41 in 36 15 36 05 Max 0 13 Nonoccurrence 36 10 36 02 Min ...

Page 164: ... Width 42 5 mm 1 67 in 36 0 mm 1 42 in Build up or replace 2 Sprocket Dedendum Diameter ø377 mm 14 84 in ø411 0 mm 16 18 in Build up or replace 3 Mounting Bolt Tightening Torque 18 kg m 130 ft lb M14 x 2 0 4 Motor Mounting Bolt Tightening Torque 18 kg m 130 ft lb M14 x 2 0 5 Travel Motor Mounting Hole ø230 0 mm 8 03 in ...

Page 165: ... Tightening torque 6 9 kg m 43 65 ft lb Track Loosening 1 Loosening track tension grease valve of tension adjusting cylinder will drain grease and loosen tracks Loosen track tension grease valve slowly 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 ful...

Page 166: ...rack from idler using a steel bar Track Installation Track installation operation may very dangerous as it should be done with machine inclined Never move machine during removal operation so machine may not be tipped over 1 Track installation Lift machine in one side using front and install wood block under machine Index track 2 with sprocket teeth and then install it on top of idler For steel tra...

Page 167: ...t to remove track roller 3 Mount track roller for steel track NOTE Be sure to install a washer for steel track 4 Install guide plate NOTE Tightening torque 4 30 kg m 31 1 ft lb 5 Assemble idler for steel track 6 After installing tracks adjust track tension Figure 24 FG008482 Washer for Steel Crawler Figure 25 Guide Plate FG008483 Figure 26 ...

Page 168: ... torque 34 50 kg m 250 ft lb 4 Remove guide plate 5 Install idlers for rubber track 6 After assembling rubber tracks adjust track tension NOTE Track shoe link pins and bushings wear with normal usage reducing track tension Periodic adjustment is necessary to compensate for wear and it may also be required by working conditions Figure 27 Figure 28 FG008482 Washer for Steel Crawler Figure 29 Guide P...

Page 169: ...625 Page 23 Track Assembly IDLER Parts List 3 5 4 8 1 2 6 5 7 3 FG011233 Figure 30 Reference Number Description 1 Idler 2 Shaft 3 Support 4 Bushing 5 F Seal 6 O ring 7 Pin 8 Plug Reference Number Description ...

Page 170: ...3 from shaft 2 4 Remove O ring 6 using a screwdriver Once removed O ring 6 should not be reused 5 Remove floating seal 5 bushing 4 shaft 2 and plug 8 Reassembly 1 For reassembly reverse disassembly procedures Clean separated parts Coat clean gear oil or engine oil 80 0 cc 2 71 oz before assembling oil seal 5 See Track Installation on page 20 for track reassembly ...

Page 171: ...ION ADJUSTING CYLINDER Parts List FG013472 9 10 1 4 2 6 7 8 3 5 Figure 31 Reference Number Description 1 Flange 2 Cylinder 3 Rod 4 Spring 5 Valve 6 U packing 7 Back up Ring 8 Dust Ring Nok DSI 50 9 Nut 10 Split Pin Reference Number Description ...

Page 172: ... great to O ring and Dust wiper 2 Assemble rod 3 to cylinder 2 First inject grease into cylinder Install track tension valve 5 into tension adjusting cylinder rod until two threaded portions contact threaded hole and then assemble rod At this time ensure that grease is drained from grease drain port and then tighten track tension grease valve NOTE Track tension grease valve tightening torque 6 9 k...

Page 173: ...y LOWER ROLLER Steel Track Parts List FG013473 7 3 5 6 4 1 8 2 4 6 5 3 7 Figure 32 Reference Number Description 1 Roller 2 Shaft 3 Collar 4 Bushing 5 Floating Seal 6 O ring 7 Retaining Ring 8 Plug PT1 8 Reference Number Description ...

Page 174: ... Assembly Page 28 Rubber Track Parts List FG011235 7 6 5 4 3 2 1 8 3 4 5 6 7 Figure 33 Reference Number Description 1 Body 2 Shaft 3 Bushing 4 F Seal 5 O ring 6 Collar 7 Snap Ring 8 Plug Reference Number Description ...

Page 175: ...8 then Collar 6 4 Remove floating seal 4 and bushing 3 5 Use a screwdriver to take out O ring 5 Once removed oil seal should not be reused 6 Remove shaft 2 from body 1 Reassembly 1 Clean separated parts with cleansing oil 2 Inject clean gear oil or engine oil 100 0 cc 3 38 oz before assembling O ring 5 3 See Track Installation on page 20 to assemble tracks ...

Page 176: ...Page 30 UPPER ROLLER Parts List Figure 34 FG013473 7 3 5 6 4 1 8 2 4 6 5 3 7 Reference Number Description 1 Roller 2 Shaft 3 Collar 4 Bushing 5 Floating Seal 6 O ring 7 Retaining Ring 8 Plug PT1 8 Reference Number Description ...

Page 177: ...4 Use a screwdriver to take out O ring 6 NOTE Once removed oil seal should not be reused 5 Remove floating seal 5 and bushing 4 then shaft 2 from body Reassembly 1 Clean separated parts with cleaning fluid 2 Inject clean gear oil or engine oil 100 0 cc 3 38 oz before assembling O ring 6 3 See Track Installation on page 20 to assemble tracks ...

Page 178: ...ssembly 1 Remove tracks 2 Remove sprocket clamping bolt 1 and sprocket 2 from travel motor Reassembly 1 Install sprocket to travel motor and tighten clamping bolt NOTE Tightening torque 11 50 kg m 83 ft lb 2 Assembly tracks 1 2 FG008479 Figure 35 ...

Page 179: ...1Engine and Drive Train ...

Page 180: ......

Page 181: ...SP001693 Page 1 Engine q SP001693 ENGINE SP001693 Engine Edition 1 ...

Page 182: ...SP001693 Engine Page 2 MEMO ...

Page 183: ...lant 43 Principal Engine Specifications 46 Engine Service Standards 47 Tightening Torques for Standard Bolts and Nuts 48 Periodic Maintenance 50 Before You Begin Servicing 50 Introduction 64 Periodic Maintenance Schedule 65 Periodic Maintenance Procedures 67 Engine 92 Before You Begin Servicing 92 Introduction 95 Cylinder Head Specifications 95 Camshaft and Timing Gear Train Specifications 97 Cran...

Page 184: ...jection Timing 189 Fuel Injectors 194 Cooling System 200 Before You Begin Servicing 200 Introduction 203 Cooling System Diagram 203 Engine Coolant Pump Components 204 Engine Coolant System Check 205 Engine Coolant Pump 205 Lubrication System 210 Before You Begin Servicing 210 Introduction 212 Oil Pump Service Information 212 Lubrication System Diagram 213 Checking Engine Oil Pressure 214 Trochoid ...

Page 185: ...ocation 252 Dynamo Wiring Diagram 253 Operation of Dynamo 253 Dynamo Standard Output 254 Testing of Dynamo 255 Dynamo 256 Electric Wiring 259 Electric Wiring Precautions 259 Electrical Wire Resistance 260 Battery Cable Resistance 261 Electrical Wire Sizes Voltage Drop 262 Conversion of Awg to European Standards 263 Troubleshooting 264 Special Service Tools 264 Troubleshooting by Measuring Compress...

Page 186: ...SP001693 Engine Page 6 MEMO ...

Page 187: ...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 Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 188: ...team can spurt out during engine operation if the cap is loose Always check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury Figure 2 DANGER Explosion Hazard Keep the area around the battery well ventilated While the engine is running or the battery is charging hydrogen gas is produced which can be easily ignited Keep sparks ope...

Page 189: ... Figure 4 DANGER Fire And Explosion Hazard Only use the key switch to start the engine Never jump start the engine Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion Failure to comply will result in death or serious injury HDO1015I Figure 5 DANGER Fire And Explosion Hazard Diesel fuel is flammable and explosive under certain conditions If the unit has an e...

Page 190: ...l ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury HDO1015I Figure 7 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 ...

Page 191: ...eck for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation whichever comes first Failure to comply will result in death or serious injury Figure 10 DANGER Explosion Hazard Never chec...

Page 192: ...ody parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the machine Never start the engine in gear Sudden movement of the engine and or machine could cause death or serious personal injury Never operate the engine without t...

Page 193: ... Alcohol And Drug Hazard Never operate the engine while you are under the influence of alcohol or drugs Never operate the engine when you are feeling ill Failure to comply could result in death or serious injury HAOA020L Figure 16 WARNING Exposure Hazard Wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task at hand Never wear jewelry unbutt...

Page 194: ...skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury FG009150 Figure 19 WARNING High pressure Hazard Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in...

Page 195: ...ne may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury HAOA050L Figure 22 WARNING Burn Hazard Wait until the eng...

Page 196: ...rating and could seriously burn you Failure to comply could result in death or serious injury FG009152 Figure 24 WARNING To preventpossible eye injury always wear SAFETY GLASSES while servicing the engine FG009153 Figure 25 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...

Page 197: ...fe engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury FG009152 Figure 27 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...

Page 198: ...t engine damage and to comply with EPA ARB warranty requirements Only use clean diesel fuel Never remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog CAUTION 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 a...

Page 199: ...rface 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 in any direction engine oil may enter the combustion chamber causing excessive engine speed and white exhaust smoke This may cause serious engine damage CAUTION Observe the following environmental operati...

Page 200: ...n this manual such as the operator s console are for a typical engine installation Refer to the documentation supplied by the optional equipment manufacturer for specific operation and maintenance instructions CAUTION If any indicator illuminates during engine operation stop the engine immediately Determine the cause and repair the problem before you continue to operate the engine CAUTION Only use...

Page 201: ...at 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 turbocharger if equipped and exhaust system to cool slightly before the engine itself is shut down CAUTION Never use an engine starting aid such as ether Engine damage will result FG009156 Figure 29 CAUTION Always be environ...

Page 202: ... prolonged operation at minimum or maximum engine speeds and loads for the next four to five hours During the break in period carefully observe the engine oil pressure and engine temperature During the break in period check the engine oil and coolant levels frequently CAUTION Never attempt to modify the engine s design or safety features such as defeating the engine speed limit control or the fuel...

Page 203: ... applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy 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...

Page 204: ...requently Never operate the engine with the air cleaner element s removed This may allow foreign material to enter the engine and damage it CAUTION The maximum air intake restriction in terms of differential pressure measurement must not exceed 0 90 psi 6 23 kPa 635 mmAq Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value CAUTION It is important...

Page 205: ...load test 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 Damage to the alternator will result CAUTION Do not remove the positive battery cable from alternator terminal B while the engine is operating Damage to the alternator will result CAUTION Do not turn...

Page 206: ...r install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines CAUTION After marking the position of the pump drive gear do not rotate the engine crankshaft Rotating the crankshaft will cause the fuel injection pump to become...

Page 207: ...nsult authorized DOOSAN dealer or distributor before using the equipment in such an environment or the warranty is voided CAUTION 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 on the wiring diagram The starter motor will malfunction or break down if the resistance is higher than the speci...

Page 208: ...r 5 000 rpm dynamo will damage the current limiter and other electrical equipment 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 CAUTION Avoid damage to the turbocharger or the engine Do not spray blower wash fluid or...

Page 209: ...e position during the reassembly process CAUTION Each pressure adjusting shim remived or added changes the pressure threshold by approximately 275 psi 1 9 MPa 19 kgf cm2 Addingadjusting shims increases the threshold pressure Removing adjusting shims reduces the pressure threshold CAUTION Do not rotate the crankshaft with the injection pump removed CAUTION Keep the piston pin parts piston assemblie...

Page 210: ...ssembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed Never attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof s...

Page 211: ...ne Cooling Fan End 4 Engine Coolant Pump 5 Engine Cooling Fan 6 Crankshaft V Pulley 7 V Belt 8 Side Filler Port Engine Oil 9 Drain Plug Engine Oil 10 Fuel Injection Pump 11 Engine Oil Cooler 12 Engine Oil Filter 13 Dipstick Engine Oil 14 Eco Governor 15 Intake Manifold 16 Fuel Filter 17 Fuel Inlet 18 Fuel Return to Fuel Tank 19 Top Filler Port Engine Oil 20 Rocker Arm Cover 21 Air Intake Port From...

Page 212: ...ine Nameplate EPA ARB Certification Label 97 68 EC Emission Control Label 4TNV98 E On the top of the locker arm cover flywheel end Figure 32 right 4 On the top of the locker arm cover Center Figure 32 right 1 On the top of the locker arm cover fan end Figure 32 right 3 ...

Page 213: ...ents from the diesel fuel Periodic replacement of the fuel filter is necessary See Periodic Maintenance Schedule on page 65 for the replacement frequency Please note that the word diesel is implied throughout this manual when the word fuel is used Fuel Filter Water Separator The fuel filter water separator removes contaminants sediments and water from the diesel fuel going to the fuel filter This ...

Page 214: ...in of the driven machine Constant speed engines for e g generator use do not require accelerator sensors because the engine speed can be shifted via a switch on the operator s console Optional CAN communication capability is available as an option Fault indicator Is installed on the operator s console If a fault occurs in the E ECU or Eco governor the fault indicator flashes alerting the operator ...

Page 215: ...lant temperature When the coolant temperature reaches a predetermined value this feature returns the engine speed to the normal low idle setting thus reducing the warm up time High idling speed down Optional Decreases the high idling speed depending on the engine coolant temperature When the coolant temperature falls to a predetermined value this feature returns the engine speed to the normal high...

Page 216: ...ansferred to the air Radiator Cap The radiator cap controls the cooling system pressure The cooling system is pressurized to raise the boiling point of the engine coolant As the engine coolant temperature rises the system pressure and the coolant volume increases When the pressure reaches a preset value the release valve in the radiator cap opens and the excess engine coolant flows into the reserv...

Page 217: ...the fuel tank and fuel handling equipment clean at all times 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 The carbon residue content must not exceed 0 35 by volume Less than 0 1 ...

Page 218: ...pliers Precautions and concerns regarding the use of bio fuels 1 Free methanol in FAME may result in corrosion of aluminum and zinc FIE components 2 Free water in FAME may result in plugging of fuel filters and increased bacterial growth 3 High viscosity at low temperatures may result in fuel delivery problems injection pump seizures and poor injection nozzle spray atomization 4 FAME may have adve...

Page 219: ...xplosion 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 the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vapors Never place diesel f...

Page 220: ...lter and draining the fuel filter water separator or replacing a fuel system component To prime the fuel system 1 Turn the key to the ON position for 10 15 seconds This will allow the electric fuel pump t80o prime the fuel system 2 Never use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring g...

Page 221: ... operation and then every 250 hours thereafter 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 TBN mgKOH g test method JIS K 201 5 2 2 HCI ASTM D4739 HCI CA...

Page 222: ...Figure 38 lines on the dipstick 5 Fully reinsert the dipstick Adding Engine Oil 1 Make sure the engine is level 2 Remove the oil cap 4 Figure 38 3 Add the indicated amount of engine oil at the top or the side engine oil filler port 5 Figure 38 4 Wait three minutes and check the oil level 5 Add more oil if necessary 6 Reinstall the oil cap 4 Figure 38 and hand tighten Over tightening may damage the...

Page 223: ...ven death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury HAOA050L Figure 40 WARNING Burn Hazard Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury FG009154 Figure 41 CAU...

Page 224: ...tructions on the coolant container Water quality is important to coolant performance DOOSAN recommends that soft distilled or demineralized water beused to mix with coolants NEVER mix extended or long life coolants and conventional green coolants NEVER mix different types and or colors of extended life coolants Replace the coolant every 1000 engine hours or once a year CAUTION Only use the engine ...

Page 225: ...e radiator cap 2 Figure 42 Align the tabs on the back side of the radiator cap with the notches on the engine coolant filler port Press down and turn the cap clockwise about 1 3 of a turn 5 Remove the cap on the reserve tank 3 Figure 42 and fill it to the LOW COLD mark 4 Figure 42 with engine coolant Reinstall the cap 6 Check the hose 5 Figure 42 that connects the reserve tank 3 Figure 42 to the r...

Page 226: ...ooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure Rated Engine Speed 0 29 0 39 3 0 4 0 MPa Low Idle Speed 0 06 0 6 MPa Starting System Electric Starting Starter Motor DC12V 2 3 kW Charging system Alternator DC12V 40A Recommended Battery Capacity 12V 64Ah 5h rating Starting aid device Air Heater 12VDC 500w Dimensions L x W x H 719...

Page 227: ...4TNV98 E 483 513 psi 3 33 3 53 MPa 34 36 kgf cm2 384 414 psi 2 65 2 85 MPa 27 29 kgf cm2 See Troubleshootin g by Measuring Compression Pressure on page 265 Deviation Between Cylinders All Models 29 43 psi 0 2 0 3 MPa 2 3 kgf cm2 Oil Pressure Switch Operating Pressure 5 8 8 8 psi 0 04 0 06 MPa 0 4 0 6 kgf cm2 Thermostat Valve Opening Temperature Full Opening Lift Temperature See Thermostat on page ...

Page 228: ...ightened to aluminum alloy Item Nominal Thread Diameter x Pitch Tightening Torque Remarks Hexagon Bolt 7T and Nut M6 x 1 0 mm 7 9 ft lb 87 104 in lb 9 8 11 8 N m 1 0 1 2 kgf m Use 80 of the value at left when the tightening part is aluminum Use 60 of the value at left for 4T bolts and lock nuts M8 x 1 25 mm 17 21 ft lb 200 251 in lb 22 6 28 4 N m 2 3 2 9 kgf m M10 x 1 5 mm 33 40 ft lb 44 1 53 9 N ...

Page 229: ... lb 19 6 18 734 N m 2 0 3 5 kgf m M12 18 25 ft lb 24 5 34 3 N m 2 5 3 5 kgf m M14 29 36 ft lb 39 2 49 0 N m 4 0 5 0 kgf m M16 36 43 ft lb 49 0 58 8 N m 5 0 6 0 kgf m Note Torque values shown in this manual are for clean non lubricated fasteners unless otherwise Item Nominal Thread Diameter x Pitch Tightening Torque Remarks ...

Page 230: ... switch to start the engine Never jump start the engine Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion Failure to comply will result in death or serious injury HAOA060L Figure 48 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 ...

Page 231: ...es of ignition Failure to comply will result in death or serious injury HDO1015I Figure 50 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 has been out of service Rubberized...

Page 232: ...il hay or dried grass close to the engine during engine operation or shortly after shutdown Failure to comply will result in death or serious injury HDO1015I Figure 53 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 HDO1042L Figure 54 DANGER Crush Haza...

Page 233: ... Hazard Diesel fuel is extremely flammable and explosive under certain conditions Place an approved container under the air bleed port when you prime the fuel system Never use a shop rag to catch the fuel Wipe up any spills immediately ALWAYS close the air bleed port after you complete priming the system Wear eye protection The fuel system is under pressure and fuel could spray out when you open t...

Page 234: ...r serious injury FG009148 Figure 58 WARNING Sever Hazard Keep hands and other body parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the machine Never start the engine in gear Sudden movement of the engine and or machine ...

Page 235: ...e 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 Failure to comply could result in death or serious injury Figure 60 WARNING Alcohol And Drug Hazard Never operate the engine while you are under the influence of ...

Page 236: ...luid to come in contact with clothing skin or eyes Severe burns could result Always wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury FG009150 Figure 63 WARNING High p...

Page 237: ...lly start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury HAOA050L Figure 66 WARNING Burn Hazard If you must drain the engine oil w...

Page 238: ...el 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 Never remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog CAUTION Only use the engine oil specified Other engine oils may affect warranty co...

Page 239: ...eating the engine speed limit control or the diesel fuel injection quantity control Modifications may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may void its warranty Be sure to use genuine replacement parts CAUTION Observe the following environmental operating conditions to maintain engine performance and avoid premature...

Page 240: ...e oil may not flow easily Contact your authorized DOOSAN dealer or distributor if the engine will be operated outside of this standard temperature range CAUTION Never hold the key in the START position for longer than 15 seconds or the starter motor will overheat CAUTION For maximum engine life DOOSAN recommends that when shutting the engine down you allow the engine to idle without load for five ...

Page 241: ...aks coolant leaks and for proper operation of the indicators and or gauges During the first hour of operation vary the engine speed and the load on the engine Short periods of maximum engine speed and load are desirable Avoid prolonged operation at minimum or maximum engine speeds and loads for the next four to five hours During the break in period carefully observe the engine oil pressure and eng...

Page 242: ...tect the air cleaner turbocharger if equipped and electric components from damage when you use steam or high pressure water to clean the engine CAUTION Never overfill the engine with engine oil Always keep the oil level between the upper and lower lines on the oil cap dipstick CAUTION Never use high pressure water or compressed air at greater than 28 psi 193 kPa 19 686 mm Aq or a wire brush to cle...

Page 243: ...vel 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 Be sure to tighten the air vent screw after the water has drained out CAUTION When the engine is operated in dusty conditions clean the air cleaner element more frequently Never operate...

Page 244: ...acement parts are needed Genuine replacement parts help ensure long engine life Required EPA ARB Maintenance USA Only To maintain optimum engine performance and compliance with the Environmental Protection Agency EPA Regulations Non road Engines and the California Air Resources Board ARB California it is essential that you follow the See Periodic Maintenance Schedule on page 65 and See Periodic Ma...

Page 245: ...tant to keep the engine in good operating condition The following is a summary of maintenance items by periodic maintenance intervals Periodic maintenance intervals vary depending on engine application loads diesel fuel and engine oil used and are hard to establish definitively The following should be treated only as a general guideline CAUTION Establish a periodic maintenance plan according to th...

Page 246: ...ine Oil R 1st time R 2nd and after Replace Engine Oil Filter Engine Speed Control Check and Adjust Governor Lever and Engine Speed Control C C Emission Control Warranty Inspect Clean and Test Fuel Injectors D Inspect Turbocharger Blower Wash as Necessary D Inspect Crankcase Breather System D Fuel Check and Refill Fuel Tank Level C Drain Fuel Tank C Drain Fuel Filter Water Separator C Check Fuel Fi...

Page 247: ...ry 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 CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contami...

Page 248: ...der the engine to collect waste oil 6 Remove the oil drain plug 1 Figure 76 from the engine oil pan Allow oil to drain 7 After all oil has been drained from the engine reinstall the oil drain plug 1 Figure 76 and tighten to 14 17 ft lb 19 6 23 5 N m 2 0 2 4 kgf m 8 Dispose of used oil properly FG009156 Figure 73 CAUTION Always be environmentally responsible Follow the guidelines of the EPA or othe...

Page 249: ...ew engine oil to the engine as specified in Adding Engine Oil on page 4 14 5 Warm up the engine by running it for five minutes and check for any engine oil leaks 6 After engine is warm shut it off and let it sit for 10 minutes 7 Recheck the engine oil level 8 Add engine oil 5 Figure 77 as needed until the level is between the upper 2 Figure 77 and lower lines 3 Figure 77 shown on the dipstick 1 Fi...

Page 250: ...the adjusting bolt 1 Figure 79 and move the alternator 2 Figure 79 with a pry bar 3 Figure 79 to tighten the V belt to the desired tension Then tighten the adjusting bolt 3 Tighten the V belt to the proper tension There must be clearance 1 Figure 80 between the V belt and the bottom of the pulley groove If there is no clearance 2 Figure 80 between the V belt and the bottom of the pulley groove rep...

Page 251: ...eath 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 components that operate at high temperatures such as the exhaust system to cool slightly before the engine itself is shut down FG009156 Figure 82 CAUTION Always be environmentally responsible Follow the guid...

Page 252: ...old it to prevent the fuel from spilling Wipe up all spilled fuel 4 Clean the filter mounting surface and apply a small amount of diesel fuel to the gasket of the new fuel filter 5 Install the new fuel filter Turn to the right 2 Figure 83 and hand tighten it only until it comes in contact with the mounting surface Tighten to 14 17 ft lb 19 6 23 5 N m 2 0 2 4 kgf m or one additional turn using the ...

Page 253: ...you remove any fuel system component Failure to comply will result in death or serious injury CAUTION 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 Be sure to ...

Page 254: ...follows 1 Position an approved container under the fuel filter water separator 1 Figure 86 to collect the contaminants 2 Close 2 Figure 86 the fuel cock 3 Figure 86 3 Loosen the drain cock 4 Figure 86 at the bottom of the fuel filter water separator Drain any water collected inside 4 Hand tighten the drain cock 5 Open the fuel cock 3 Figure 86 6 Be sure to prime the diesel fuel system when you are...

Page 255: ...entally drink acid drink a large quantity of water or milk beaten egg or vegetable oil Call a doctor or poison prevention center immediately When working with batteries always wear safety glasses or goggles Battery generates hydrogen gas so there is a danger of an explosion Do not bring lighted cigarettes near the battery or do anything that will cause sparks Before working with batteries shut dow...

Page 256: ...ough the charging indicator GREEN Sufficiently charged BLACK Insufficient charged TRANSPARENT Replace battery Check the Battery Terminals Be certain that battery is held securely in its compartment Clean the battery terminals and the battery cable connectors A solution of baking soda and water will neutralize acid on the battery surface terminals and cable connectors Petroleum jelly or grease can ...

Page 257: ...d not be removed when cleaning or replacing the outer element The inner element is used to prevent dust from entering the engine while servicing the outer element 6 Replace the element with a new one if the element is damaged excessively dirty or oily 7 Clean inside of the air cleaner cover 8 Install the element into the air cleaner case 4 Figure 89 9 Reinstall the air cleaner cover making sure yo...

Page 258: ...the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury FG009156 Figure 93 CAUTION Always be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for t...

Page 259: ...specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap Never mix different types of engine oil This may adversely affect the lubricating properties of the engine oil Never overfill Ov...

Page 260: ...ee Check and Adjust Cooling Fan V Belt on page 80 Clean Air Cleaner Element Note that a typical air cleaner is shown in Figure 98 and Figure 100 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 1 Unlatch and remove the air cleaner cover 1 Figure 98 2 Remove the element ...

Page 261: ...ne if the element is damaged excessively dirty or oily 7 Clean inside of the air cleaner cover 8 Install the element into the air cleaner case 4 Figure 98 9 Reinstall the air cleaner cover making sure you match the arrow 5 Figure 98 on the cover with the arrow on the case 6 Figure 98 10 Latch the air cleaner cover to the case FG009152 Figure 99 CAUTION FLYING OBJECT HAZARD Always wear eye protecti...

Page 262: ...ter element Replace Fuel Filter CAUTION The maximum air intake restriction in terms of differential pressure measurement must not exceed 0 90 psi 6 23 kPa 635 mmAq Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value HDO1015I Figure 101 DANGER Fire And Explosion Hazard Diesel fuel is flammable and explosive under certain conditions When you remov...

Page 263: ...such as the exhaust system to cool slightly before the engine itself is shut down FG009156 Figure 102 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 ...

Page 264: ...a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury FG009156 Figure 105 CAUTION Always be environmentally responsible Follow the guidelines of the EPA or other govern...

Page 265: ... hold the cup to prevent fuel from spilling If you spill any fuel clean up the spill completely 6 Remove the float ring 8 Figure 106 from the cup Pour the contaminants into the container and dispose of it properly 7 Clean the element 9 Figure 106 and inside cup Replace the element if it is damaged 8 Install the element and O ring in the bracket 9 Position the float ring in the cup 10 Check the con...

Page 266: ...t 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 See Intake Exhaust Valve and Guide on page 95 ...

Page 267: ... The EGR valve is a key component for cleaning exhaust gas To prevent the valve from deteriorating in exhaust gas recirculation performance due to carbon accumulation inspect clean and test the valve at least every 1500 hours Consult your local DOOSAN dealer for this service FG009150 Figure 107 WARNING High pressure Hazard Avoid skin contact with the high pressure diesel fuel spray caused by a fue...

Page 268: ...a passage that allows crankcase fumes to be routed to the intake manifold To inspect the diaphragm and spring 3 Figure 108 1 Remove the bolts retaining the diaphragm cover 4 Figure 108 2 Remove the diaphragm cover spring diaphragm plate 5 Figure 108 and diaphragm 3 Inspect the diaphragm for tears Inspect the spring for distortion Replace components if necessary 4 Reinstall the diaphragm diaphragm ...

Page 269: ...ighten the radiator cap securely after you check the radiator Steam can spurt out during engine operation if the cap is loose Always check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury HAOA050L Figure 110 WARNING Burn Hazard Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn...

Page 270: ...f the radiator and drain the engine coolant 4 Drain the coolant from the engine block On models not equipped with an oil cooler remove the coolant drain plug 1 Figure 114 from the engine block FG009156 Figure 112 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...

Page 271: ... fuel system and engine coolant system hoses If they are cracked or degraded replace them Replace the hoses at least every two years Lap the Intake and Exhaust Valves Adjustment is necessary to maintain proper contact of the valves and seats See Inspection of Intake and Exhaust Valves on page 114 Figure 115 FG009156 Figure 116 CAUTION Always be environmentally responsible Follow the guidelines of ...

Page 272: ...he engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury FG009153 Figure 119 WARNING Fume Burn Hazard Always read and follow safety related p...

Page 273: ...y clean the oil cap dipstick and the surrounding area before you remove the cap Never mix different types of engine oil This may adversely affect the lubricating properties of the engine oil Never overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an intern...

Page 274: ...tion lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 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 CAUTION Keep the p...

Page 275: ...Valve Seat on page 116 Exhaust 90 Seat Correction Angle 40 150 Inspection Item Standard Limit Reference Page Intake Guide Inside Diameter 0 2756 0 2762 in 7 000 7 015 mm 0 2787 in 7 08 mm See Inspection of Valve Guides on page 114 Valve Stem Outside Diameter 0 2734 0 2740 in 6 945 6 960 mm 0 2717 in 6 90 mm Valve Stem Bend 0 0016 0 0028 in 0 040 0 070 mm 0 0067 in 0 17 mm Exhaust Guide Inside Diam...

Page 276: ...Reference Page Free Length 1 5630 in 39 7 mm 1 5433 in 39 2 mm See Inspection of Valve Springs on page 116 Squareness 0 0551 in 1 4 mm Inspection Item Standard Limit Reference Page Arm Shaft Hole Diameter 0 7283 0 7291 in 18 500 18 520 mm 0 7311 in 18 57 mm See Inspection of Rocker Arm Assembly on page 113 Shaft Outside Diameter 0 7272 0 7280 in 18 470 18 490 mm 0 7260 in 18 44 mm Oil Clearance 0 ...

Page 277: ... 50 100 mm Camshaft Outside Diameter 1 9650 1 9659 in 49 910 49 935 mm 1 9636 in 49 875 mm Oil Clearance 0 0026 0 0045 in 0 065 0 115 mm 0 0089 in 0 225 mm Flywheel End Bore Inside 1 9685 1 9695 in 50 000 50 025 mm 1 9724 in 50 100 mm Camshaft Outside Diameter 1 9655 1 9665 in 49 925 49 950 mm 1 7673 in 49 890 mm Oil Clearance 0 0020 0 0039 in 0 050 0 100 mm 0 0083 in 0 210 mm Inspection Item Stan...

Page 278: ... 902 mm Bearing Inside Diameter 2 5590 2 5598 in 65 000 65 020 mm Bearing Insert Thickness 0 0785 0 0791 in 1 995 2 010 mm Oil Clearance 0 0015 0 0027 in 0 038 0 068 mm 0 0059 in 0 150 mm Inspection Item Standard Limit Reference Page Crankshaft End Play All Models 0 0051 0 0091 in 0 13 0 23 mm 0 0110 in 0 28 mm See Removal of Crankshaft on page 138 Inspection Item Standard Limit Reference Page Pis...

Page 279: ... 125 mm 0 0096 in 0 245 mm End Gap 0 017 0 0256 in 0 450 0 650 mm 0 0287 in 0 730 mm Oil Ring Ring Groove Width 0 1187 0 1193 in 3 015 3 030 mm 0 1232 in 3 130 mm Ring Width 0 1169 0 1177 in 2 970 2 990 mm 0 1161 in 2 950 mm Side Clearance 0 0010 0 0024 in 0 025 0 060 mm 0 0071 in 0 180 mm End Gap 0 0098 0 0177 in 0 250 0 450 mm 0 0217 in 0 550 mm Inspection Item Standard Limit Reference Page Wris...

Page 280: ...ion of Tappets on page 144 Tappet Stem Outside Diameter 0 4715 0 4720 in 11 975 11 990 mm 0 4707 in 11 955 mm Oil Clearance 0 004 0 0017 in 0 010 0 043 mm 0 0033 in 0 083 mm Model Inspection Item Standard Limit Reference Page Cylinder Inside Diameter 3 8583 3 8594 in 98 000 98 030 mm 3 8634 in 98 130 mm See Inspection of Cylinder Block on page 142 Cylinder Bore Roundness 0 0004 in 0 01 mm or less ...

Page 281: ... lb 53 9 58 8 N m 5 5 6 0 kgf m Applied Flywheel Bolt M14 x 1 5 mm 137 152 ft lb 186 2 205 8 N m 19 21 kgf m Applied Main Bearing Cap Bolt M11 x 1 25 mm 80 87 ft lb 108 1 117 9 N m 11 0 12 0 kgf m Applied Crankshaft Pulley Bolt M14 x 1 5 mm 80 94 ft lb 107 9 127 5 N m 11 0 13 0 kgf m Applied Fuel Injector Bolt M8 x 1 25 mm 17 21 ft lb 22 6 28 4 N m 2 3 2 9 kgf m Not Applied Fuel Pump Drive Gear Nu...

Page 282: ...alve Spring Compressor For Removal Installation of Valve Spring Part No 129100 92630 6 Installer for Installing Valve Stem Seal Locally manufactured 4TNV98 L1 L2 d1 d2 Model 0 787 in 20 mm 2 953 in 75 mm 0 256 in 6 5 mm 0 394 in 10 mm FG010215 4TNV98 L1 L2 d1 d2 Model 0 276 in 7 mm 2 362 in 60 mm 0 512 in 13 mm 0 630 in 16 mm FG010216 4TNV98 L1 L2 d1 d2 Model 0 787 in 3 937 in 1 181 in 1 299 in FG...

Page 283: ...r For Installing Piston Part No 95550 002476 The Piston Insertion Tool is Applicable for 2 362 4 921 in 60 125 mm Diameter Pistons 11 Piston Ring Expander For Removal Installation of Piston Ring Available Locally No Illustration Tool name Applicable model and tool size 4TNV98 L1 L2 d1 d2 Model 0 709 in 2 756 in 1 968 in 2 087 in FG010228 18 mm 70 mm 50 mm 553 mm Model Yanmar Part No Cylinder Bore ...

Page 284: ...8 C1 FG008874 No Illustration Tool name Applicable model and tool size 1 Dial Indicator Locally Available Measure shaft bend and end play 2 Test Indicator Locally Available Measurements of narrow or deep portions that cannot be measured by dial gauge 3 Magnetic Stand Locally Available For holding the dial gauge when measuring 4 Micrometer Locally Available For measuring the outside diameters of cr...

Page 285: ... Available For measuring of valve recession 8 Square Locally Available For measuring valve spring inclination and straightness of parts 9 V Block Locally Available For measuring shaft bend 10 Torque Wrench Locally Available For tightening nuts and bolts to the specified torque 11 Feeler Gauge Locally Available For measuring piston ring gaps piston ring clearance and valve adjustment clearance No I...

Page 286: ...SP001693 Engine Page 106 4 valve Cylinder Head 4 Valve Cylinder Head Components Figure 121 ...

Page 287: ...justing Screw Lock Nut Primary 15 Rocker Arm Shaft Aligning Stud 16 Fuel Injector Retainer 17 Valve Stem Seal 18 Valve Guide 19 Cylinder Head 20 Intake Valve 21 Exhaust Valve 22 Cylinder Head Gasket 23 Fuel Injector Nozzle Protector 24 Fuel Injector Nozzle Seat 25 Valve Spring 26 Valve Bridge Guide 27 Spring Retainer 28 Valve Keepers 29 Valve Bridge 30 Valve Bridge Seat 31 Valve Adjusting Screw Lo...

Page 288: ... not necessary to remove the connecting coupler 5 Remove the turbocharger to intake manifold hose 1 Figure 123 if equipped 6 Disconnect the electrical wire from the intake air heater 12 Figure 123 7 Remove the intake manifold bolts 11 Figure 123 Remove the intake manifold 10 Figure 123 Discard the intake manifold gasket 9 Figure 123 8 Disconnect the turbocharger oil supply 2 Figure 123 and the ret...

Page 289: ...ade screwdriver Figure 124 to remove the fuel injection line grommets 1 Figure 125 from the valve cover 3 Figure 125 and fuel injectors 2 Figure 125 There is a notch at the 3 o clock position in the valve cover opening to insert the screwdriver 3 Remove the valve cover nuts 4 Figure 125 4 Remove the O ring 5 Figure 125 on each valve cover nut 5 Remove the valve cover 3 Figure 125 Discard the valve...

Page 290: ...ock arm so they can be reinstalled with the original matching valve and pushrod 1 Remove the rocker arm shaft alignment studs 5 Figure 127 from the rocker arm shaft supports 6 Figure 127 2 Slide the supports wave washers Figure 127 7 rocker arms 8 Figure 127 and fuel injector rerainers 4 Figure 127 off the rocker shaft 1 Figure 127 leaving these parts in order on the bench surface NOTE Figure 127 ...

Page 291: ...e valve springs Figure 130 3 Remove the valve keepers 1 Figure 131 4 Slowly release the tension on the valve spring 5 Remove the spring retainer 2 Figure 131 valve spring 3 Figure 131 6 Repeat the procedure with all the remaining valves NOTE If the valves are to be reused identify them so they can be installed in their original location 7 Remove the injector nozzle protectors 6 Figure 131 and the ...

Page 292: ... that are obviously discolored heavily pitted or otherwise damaged Discard any parts that do not meet its specified limit Figure 132 FG009153 Figure 133 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 CAUTION Any ...

Page 293: ...rm Shaft Hole Diameter Use a telescoping gauge and micrometer to determine if the inside diameter of all the rocker arm support brackets and the rocker arms Figure 135 are within the specified limits See Rocker Arm and Shaft on page 96 for the service limit Inspect the contact areas 1 Figure 135 for excessive wear or damage Rocker Arm Shaft Outside Diameter Use a micrometer to measure the rocker a...

Page 294: ...he bench Use a straight edge and feeler gauge to measure cylinder head distortion Figure 138 Measure diagonally and along each side See Cylinder Head on page 95 for the service limit If distortion exceeds the service limit resurface or replace the cylinder head Remove only enough material to make the cylinder head flat but do not remove more than 0 008 in 0 20 mm Inspection of Intake and Exhaust V...

Page 295: ... the service limit Valve Recession NOTE The valve guides must be installed to perform this check Insert the valves into their original locations and press them down until they are fully seated Use a depth micrometer Figure 141 to measure the difference between the cylinder head gasket surface and the combustion surface of each exhaust and intake valve Figure 142 See Cylinder Head on page 95 for th...

Page 296: ...Light cutting can be performed by the use of a hand operated cutter Figure 144 Valve seat diameter can be adjusted by top grinding with a 150 stone to make the seat diameter smaller and bottom grinding using a 40 stone to make the seat diameter larger Once the seat location has been corrected grind and lap the seat angle 1 Figure 144 to specification See Cylinder Head on page 95 for specifications...

Page 297: ...pect the contact surface at both ends of the valve bridge 2 Figure 147 for excessive wear or mushrooming Remove and inspect the seat 1 Figure 147 Measure the diameter of the valve bridge guide pin bore in the valve bridge and guide pin 3 Figure 147 See Rocker Arm and Shaft on page 96 for the service limit Reassembly of Cylinder Head Use new gaskets O rings and seals on reassembly of the cylinder h...

Page 298: ... after removing the valve guides from the freezer insert the valve guides 1 Figure 148 in their proper positions 3 Finish installing the valve guides 1 Figure 149 into the cylinder head to the proper height 3 Figure 149 using the valve guide installation tool 2 Figure 149 See Intake Exhaust Valve and Guide on page 95 Reassembly of Intake and Exhaust Valves Figure 148 2 3 1 FG008893 Figure 149 IMPO...

Page 299: ...aust Valve and Guide on page 95 3 Place the cylinder head assembly on its exhaust port side 4 Place all the valves 5 Figure 152 in their proper location in the cylinder head 5 Place the cylinder head on the workbench with the combustion side down Install the valve spring 3 Figure 152 and spring retainer 2 Figure 152 6 Using the valve spring compressor tool compress the valve spring 7 Insert the va...

Page 300: ...d torque in two steps as shown in the chart below Tighten in the sequence shown in Figure 154 See Special Torque Chart on page 101 for specification Reassembly of Rocker Arm Assembly 1 Reinstall the valve bridges 3 Figure 155 in their original locations and ensure each seat 4 Figure 155 is in place 2 Insert the push rods 2 Figure 155 in their original locations Figure 153 7 13 3 6 12 11 5 4 14 1 1...

Page 301: ...order 4 Position the rocker arm assembly on a flat surface Reinstall the alignment studs 5 Figure 158 5 Place the rocker arm shaft assembly onto the cylinder head 6 If removed reinstall the valve adjusting screws 2 Figure 158 and lock nuts 3 Figure 158 7 Align the push rods with their respective rocker arms 8 Reinstall and tighten the rocker arm shaft retaining bolts to the specified torque 9 Tigh...

Page 302: ...ld using a new gasket Tighten the bolts to specification 6 Reinstall the intake manifold using a new gasket Tighten the bolts to specification 7 Reconnect the fuel injector return hose and fuel injection pump coolant hoses 8 Reinstall the high pressure fuel line grommets into the valve cover 9 Reinstall the high pressure and fuel return lines See Installation of the Fuel Injectors on page 199 10 R...

Page 303: ...nder individually the cylinder to be adjustedfirst does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top deadcenter after turning Make adjustment for the remaining cylinders in the order of firing by turning the crankshaft each time To decrease the number of rotations required to check all cylinders other cylinders can also be checked as indica...

Page 304: ...er after turning and make adjustment for other cylinders in the order of firing by turning the crankshaft 180 each time 2 Rotate the crankshaft clockwise as seen from the coolant pump end to bring No 1 piston to TDC on the compression stroke while watching the rocker arm motion and the timing grid on the flywheel Position where both the intake and exhaust valves are closed 3 Make sure there is cle...

Page 305: ...2 pressure on the valve bridge 3 Figure 162 adjust the valve bridge adjusting screw 1 Figure 162 1 Figure 164 so there is zero 0 clearance 2 Figure 164 between the adjusting screw and the front valve 7 Tighten the lock nut 1 Figure 163 while holding the valve bridge 3 Figure 163 with a wrench 2 Figure 163 Verify that the valve clearance 2 Figure 164 is zero 0 NOTE Note There is a tendency for the ...

Page 306: ...e of dirt or wear NOTE There is a tendency for the clearance to decrease slightly when the lock nut is tightened It is suggested that you make the clearance adjustment is made slightly on the loose side before tightening the lock nut 11 Adjust the valve clearance 2 Figure 166 by turning the adjusting screw 4 Figure 166 until there is a slight drag on the feeler gauge when sliding it between the ro...

Page 307: ...SP001693 Page 127 Engine ...

Page 308: ...SP001693 Engine Page 128 Crankshaft and Camshaft Components Figure 167 ...

Page 309: ... Shaft 16 Idler Gear Bushing 17 Idler Gear 18 Oil Pickup O Ring 19 Oil Pickup 20 Crankshaft 21 Parallel Pin 22 Crankshaft Gear Key 23 Crankshaft Gear 24 Crankshaft Pulley 25 Main Bearing Inserts 26 Main Bearing Cap 27 Oil Pan 28 Thrust Bearings 29 Flywheel 30 Connecting Rod Cap 31 Connecting Rod Bearing Inserts 32 Connecting Rod 33 Wrist Pin Bushing 34 Circlip 35 Wrist Pin 36 Piston 37 Oil Ring 38...

Page 310: ...ng adequate weight capacity 6 Clean the engine by washing with solvent air or steam cleaning Carefully operate so as to prevent any foreign matter or fluids from entering the engine or any fuel system or electrical components remaining on the engine 7 Drain the engine oil into a suitable container Remove the oil filter 8 Remove the cylinder head See page 106 9 Remove the fuel injection pump from t...

Page 311: ...g the timing gears measure the gear backlash and determine the gear wear Check the backlash between each pair of mating gears Figure 169 If not within specification replace both mating gears See Timing Gear Backlash on page 97 for service limits NOTE Do not allow the gear being checked to move axially as excess end play could cause a false reading IMPORTANT Use care not to damage the threads in th...

Page 312: ... Figure 171 and bushing 3 Figure 171 2 Do not remove the crankshaft gear unless it is damaged and requires replacement If the gear must be removed remove it using a gear puller 3 Removal of the camshaft gear requires the camshaft be removed and placed in a press Do not remove the camshaft gear unless it or the camshaft is damaged and requires replacement See Removal of Camshaft on page 134 4 Do no...

Page 313: ...3 Page 133 Engine Removal of Oil Pan 1 Invert the engine oil pan up on the engine stand 2 Remove the oil pan 1 Figure 173 3 Remove the oil pickup tube 1 Figure 174 and O ring 2 Figure 174 Figure 173 Figure 174 ...

Page 314: ...he camshaft at least two turns to bump any sticking tappets away from the camshaft 4 Slowly pull the camshaft 2 Figure 177 assembly out of the engine being careful not to damage the front camshaft bushing NOTE If the engine is not installed on an engine repair fixture stand the engine upright on the flywheel end mounting flange Rotate the camshaft at least two turns to bump the tappets out of the ...

Page 315: ...p does not need to be repaired leaving it mounted to the timing gear case front plate will eliminate the need to re time it during assembly See Fuel Injection Pump on page 180 2 Remove the bolts 4 Figure 178 3 Remove the gear case 1 Figure 178 or front plate from the cylinder block Thoroughly clean all old sealant from the mating surfaces 4 Inspect and measure the camshaft bushing See Camshaft on ...

Page 316: ... rods to determine extent of wear Record the measurements A Remove the bearing cap Do not remove the bearing inserts at this time B Wipe oil from the bearing insert and crankshaft journal surfaces 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 IM...

Page 317: ...sely matches the width of the flattened PLASTIGAGE will indicate the bearing oil clearance G Repeat with remaining connecting rods 3 Use a wooden dowel against the connecting rod and tap the piston connecting rod assembly out of the cylinder 4 Mark the cylinder number on the piston and connecting rod Figure 180 IMPORTANT Do not rotate the crankshaft when using PLASTIGAGE A false reading may result...

Page 318: ...e piston 9 Figure 182 10 Repeat the steps until all pistons are removed and dissembled Removal of Crankshaft 1 Remove the flywheel 1 Figure 183 from the crankshaft 2 Remove the bolts from the rear oil seal assembly 2 3 Figure 183 Remove the assembly from the engine 3 Before removing the main bearing caps measure the crankshaft end play Use either of the following two methods Method A Install a dia...

Page 319: ...asurements A Wipe oil from the bearing insert andcrankshaft journal surfaces B Place a piece of PLASTIGAGE 1 Figure 187 along the full width of each bearing insert C Reinstall bearing caps and tighten to specification See Special Torque Chart on page 101 D Remove bearing caps E Compare the width of the flattened PLASTIGAGE to the graduation marks on the package 1 Figure 188 The mark that most clos...

Page 320: ...tal filings and other debris Replacement of Crankshaft Oil Seals 1 Remove the seal 2 Figure 191 from the cover 1 Figure 191 2 Apply a continuous bead of ThreeBond Liquid Gasket to the outside diameter of a new oil seal 2 Figure 191 and install in the gear case cover Apply lithium grease to the lip of the seal Figure 189 FG009153 Figure 190 WARNING Fume Burn Hazard Always read and follow safety rel...

Page 321: ...ide diameter of a new oil seal 2 Figure 192 and install in the housing Apply lithium grease to the lip of the seal Measure Crankshaft Bearing Oil Clearance Oil clearance should be checked during disassembly to determine the extent of wear and during assembly to ensure long engine life The same procedure is done for both connecting rods and main bearings Figure 192 ...

Page 322: ...originally removed On an engine with high hours the pistons rings should be replaced and the cylinder honed See Honing and Boring on page 147 or replaced The piston should be replaced as necessary 1 Clean piston ring grooves using a piston ring groove cleaning tool Follow manufacturer s instructions for correct operation 2 Wash the pistons in an appropriate solvent using a soft brush 3 Visually in...

Page 323: ... in the groove as shown Figure 197 Use a feeler gauge to measure the clearance between the piston ring and the piston ring land Record the measurements See Piston Ring on page 99 for specifications Replace the piston if not within specification 10 To measure piston ring end gap insert each compression piston ring 1 Figure 198 one at a time into the cylinder Use a piston with the piston rings remov...

Page 324: ...nd connecting rod cap Install the rod cap and tighten the bolts to the specified torque 3 Measure the inside diameter See Crankshaft on page 98 for specifications Inspection of Tappets 1 Inspect the tappet contact surfaces for abnormal wear 1 Figure 200 Normal wear will be even as shown in 2 Figure 200 Slight surface defects can be corrected using an oilstone 2 Measure the outside diameter of the ...

Page 325: ... 4 Use the color check method or Magnaflux to inspect the crankshaft for cracks Replace the crankshaft if evidence of fractures are found 5 Measure the outside diameter of each crankpin 2 Figure 203 and main bearing journal 1 Figure 203 See Crankshaft on page 98 for specifications Take measurements at several places around each bearing surface If not within specification grind the journals and ins...

Page 326: ...he gear end 1 Figure 206 intermediate 2 Figure 206 and flywheel end 3 Figure 206 bearing journals See Camshaft on page 97 for specifications Inspection of Camshaft Bushing and Bores 1 Measure the I D of the front bushing and the remaining bores in the cylinder block See Camshaft on page 97 for specifications 2 If the camshaft bushing is not within specification replace it using the appropriate ser...

Page 327: ...corrected by boring the cylinder to an oversize dimension Refer to the appropriate parts catalog for available oversize pistons and piston rings Boring a cylinder should always be done in a properly equipped machine shop A bored cylinder should always be finished with a hone to properly prepare the cylinder surface so the new piston rings will seat properly After the cylinder has been bored and ho...

Page 328: ...s to prevent rusting Reassembly of Crankshaft and Piston Components NOTE Proceed slowly Make no forced assemblies unless a pressing operation is called for All parts must be perfectly clean and lightly lubricated when assembled Use new gaskets seals and O rings during assembly Liberally apply clean engine oil to all internal parts during assembly All fasteners should be tightened to a given torque...

Page 329: ...ce of the match marks will vary but they will always be in the same locations Figure 210 IMPORTANT The piston and connecting rod must be assembled together in the correct orientation The orientation of the piston and connecting rod are different depending on engine model Piston to Connecting Rod Orientation By Model 4TNV98 E Orient the piston identification mark stamped on top of the piston on the...

Page 330: ...ted in the groove NOTE If installing new piston rings the end gap must be checked and adjusted as necessary See page 142 for specifications Use a piston ring end gap filing tool to adjust the piston ring end gap on new piston rings NOTE Reinstall the top and second piston rings with the stamped makers mark 1 Figure 213 facing the top of the piston The makers mark may vary in appearance but will al...

Page 331: ...apered face profile 5 Reinstall the top compression ring 1 Figure 214 This ring is identified by its silver color and barrel shaped face profile 6 Stagger the piston ring end gaps at 120 intervals 1 2 3 Figure 214 Figure 214 IMPORTANT The oil ring expander 4 Figure 214 end gap must be located 180 from the oil ring 3 Figure 214 end gap Figure 215 Reference Number Description 1 Top Compression Ring ...

Page 332: ...ankshaft to assure it turns freely 7 Apply threeBond Liquid Gasket to the mounting flange of the seal housing 2 Figure 217 8 Align the seal housing with the two dowel pins 9 Reinstall seal housing and seal assembly 10 Reinstall the flywheel 1 Figure 217 and tighten the bolts to the specified torque See Special Torque Chart on page 101 for specifications Installation of Pistons 1 Lubricate the pist...

Page 333: ...the connecting rod 3 Figure 219 must face the flywheel end 5 Figure 219 of the engine Figure 218 IMPORTANT Ensure the piston ring gaps are located correctly Figure 218 Reference Number Description 1 Top Compression Ring End Gap 2 Second Compression Ring End Gap 3 Oil Ring End Gap IMPORTANT The piston and connecting rod must be installed in the correct orientation The orientation of the piston to t...

Page 334: ...the cylinder block 4 Reinstall the gear case 1 Figure 221 Tighten the bolts to the specified torque Installation of Camshaft NOTE The gear housing or front plate must be reinstalled prior to installing the camshaft See Installation of Gear Case or Front Plate on page 154 1 If removed reinstall the camshaft end plate 1 Figure 222 key and timing gear 4 Figure 222 onto the camshaft using a press NOTE...

Page 335: ...Figure 222 with clean engine oil or assembly lube Slowly insert the camshaft through the front of the engine 5 Reinstall and tighten the cap screws 3 Figure 222 6 If removed reinstall the fuel injection pump Adjust the fuel injection timing the engine after installation See Adjusting Fuel Injection Timing on page 193 ...

Page 336: ...hree timing marks A B C Figure 223 are aligned 7 When all gears are properly aligned tighten the idler gear retaining bolts to specified torque See Special Torque Chart on page 101 for specifications Installation of Gear Case Cover 1 Apply a continuous bead of ThreeBond Liquid Gasket to the mounting area of the gear case cover 1 Figure 225 Be sure to circle the bolt holes 2 Reinstall and tighten t...

Page 337: ... bolt to the specified torque See Special Torque Chart on page 101 for specifications Figure 226 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 ...

Page 338: ...pickup tube 1 Figure 227 using a new O ring 2 Figure 227 2 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 3 Reinstall the oil pan and tighten the bolts securely Figure 227 Figure 228 ...

Page 339: ...lve cylinder head or See Reassembly of Cylinder Head on page 120 for the 4 valve cylinder head 3 Reinstall the engine in the machine 4 Reconnect the fuel and coolant lines 5 Reinstall the alternator 6 Reconnect and adjust the throttle cable 7 Reconnect all electrical connections 8 Fill the engine with oil and coolant 9 Reconnect the battery cables negative cable last ...

Page 340: ... EGR System EGR System Figure 229 Reference Number Description 1 Exhaust manifold 2 EGR pipe 3 EGR valve 4 Intake manifold 5 Cooling water hose EGR valve inlet 6 Cooling water hose EGR valve outlet Reference Number Description ...

Page 341: ...gine 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 Failure to comply could result in death or serious injury FG009148 Figure 232 WARNING Entanglement Hazard Stop the engine before you begin to service it Never ...

Page 342: ...water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury FG009154 Figure 235 CAUTION Coolant Hazard Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may...

Page 343: ...ting Cleaning EGR Related Components EGR Valve Each EGR valve has four built in coils The power to each of the four coil is either ON or OFF at any given time Depending on which coil is ON and which coil is OFF the step motor rotates to determine the valve lift The power to each coil is turned ON OFF by the E ECU based on the engine speed and fuel injection rate The resistances of these coils shou...

Page 344: ... by opening and shutting it 4 From the exhaust gas inlet visually check whether the valve operates correctly NOTE If the EGR valve fails to smoothly operate replace the entire valve assembly with new one NOTE If the EGR valve does not respond at all check whether there exists a voltage EGR valve signal between the connector pins If the voltage is within the standard range then replace the entire v...

Page 345: ...r liquid from entering into the motor and coupler terminals otherwise failure may result FG009153 Figure 238 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 FG009152 Figure 239 CAUTION FLYING OBJECT HAZARD Always ...

Page 346: ...in carbon cleaner kerosene or some other liquid capable of removing carbon Installing EGR Related Components Parts To install these components parts reverse the disassembly procedure described above thus install the lead valve spacer EGR valve EGR pipe EGR cooler elbow cooler cooling water hose and EGR cooling water hose exactly in this order The EGR system uses steel gaskets at the joints between...

Page 347: ...elry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 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 Never inject fuel toward ...

Page 348: ... FG009155 Figure 244 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 CAUTION Never remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments hav...

Page 349: ...he fuel lines will make it difficult to reinstall the fuel lines CAUTION After marking the position of the pump drive gear do not rotate the engine crankshaft Rotating the crankshaft will cause the fuel injection pump to become misaligned 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 ...

Page 350: ...distributor shaft a hydraulic head and a pump housing The hydraulic head has a delivery valve for each cylinder The fuel injection pump housing contains a governor and an internal camshaft The fuel is pressurized by the up and down motion of the camshaft driven single plunger It is then distributed to the proper fuel injector by the rotating distributor shaft There are two versions and sizes of th...

Page 351: ...ion allowing fuel to continue flowing and he engine to continue running To stop the engine the key switch is turned to the OFF position Current no longer flows to the stop solenoid hold coil and the solenoid plunger extends and moves the injection pump fuel rack to the closed position shutting off the fuel flow and stopping the engine Failure of the stop solenoid could result in the engine not sta...

Page 352: ...detecting a low water temperature of 10Ae or lower and the E ECU receives the corresponding signal then the E ECU causes the CSD s solenoid valve to increase the injection rate and advance the injection timing Because of this the engine speed increases by approximately 75 min 1 while the CSD is operating When the water temperature becomes 10 C or higher the CSD is turned off and the engine returns...

Page 353: ...ipped 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: ... 123 N m 11 5 12 5 kgf m Not Applied High Pressure Fuel Injection Line Nuts 22 25 ft lb 29 34 N m 3 0 3 5 kgf m Not Applied Fuel Return Line Bolts 69 87 in lb 7 8 9 8 N m 0 8 1 0 kgf m Not Applied Fuel Injection Pump Mounting Nuts 17 21 ft lb 23 28 N m 2 3 2 9 kgf m Not Applied Fuel Injector Nozzle Case Nut 30 33 ft lb 39 2 44 1 N m 4 4 5 kgf m Not Applied Fuel Injection Pump Plunger Plug 30 33 ft...

Page 355: ...er Locally Available For observing injection spray pattern of fuel injection nozzle and measuring injection pressure 2 Dial Indicator Mituotoyo 2050SB Locally Available Check and adjust fuel injection timing Extension Rod Mituotoyo 303613 Locally Available 3 Fuel Injection Pump Plunger Adapter M16 4TNV98 Z Part No 158090 51841 Mount dial indicator to fuel injection pump 4 Plunger Adapter Clamp DOO...

Page 356: ...SP001693 Engine Page 176 Fuel System Diagram Figure 247 ...

Page 357: ...el Supply Line 7 Low Pressure Gallery 8 Pressure Control Valve 9 Trochoid Pump 10 Oil Seal 11 Fuel Injection Pump Cam 12 Engine Crankcase 13 Tappet 14 High Pressure Gallery 15 Overflow Orifice 16 Accumulator 17 Timer Piston 18 Mono Plunger 19 Distributor Shaft 20 Fuel Return Line 21 High Pressure Fuel Injection Lines 22 Fuel Injector Reference Number Description ...

Page 358: ...SP001693 Engine Page 178 Fuel System Components 4 Valve Cylinder Head Figure 248 ...

Page 359: ...d Bolt 4 Fuel Injector 5 Injection Line Grommet 6 Front Plate or Timing Gear Case 7 Gear Case Cover 8 Fuel Injection Pump Drive Gear Nut 9 Lock Washer 10 Fuel Injection Pump Drive Gear Assembly DO NOT remove or loosen the four bolts that fasten the injection pump drive gear to the injection pump drive gear hub 11 Coolant Lines for Cold Start Device 12 Fuel Injection Pump Insulator 13 Diesel Fuel I...

Page 360: ... all the fuel line nuts and remove the high pressure fuel lines as an assembly being careful not to bend any of the fuel lines Be sure to protect the fuel system from contamination by covering all open connections 8 Disconnect the coolant lines from the cold start device 3 Figure 251 on the fuel injection pump Plug the open ends of the lines to minimize leakage and prevent contamination This cooli...

Page 361: ...njection pump cover from the gear case cover 16 To position the fuel injection pump for easier removal and installation install a dial indicator See Checking and Adjusting Fuel Injection Timing on page 189 into the injection pump plunger opening Using a wrench on the crankshaft pulley bolt rotate the crankshaft until the dial indicator shows that injection pump plunger is at the bottom of it s str...

Page 362: ...NV82 88 models the injection pump drive gear will remain captured in the gear case On TNV94 106 models the injection pump drive gear can be removed through the gear case cover opening 21 Once the fuel injection pump drive gear and hub assembly has popped loose from the tapered fuel injection pump drive shaft carefully remove the drive gear nut 1 Figure 256 and lock washer 2 Figure 256 22 Locate th...

Page 363: ...e 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 Figure 259 Figure 260 CAUTION Do not rotate the crankshaft with the injection pump removed CAUTION Never remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed...

Page 364: ...model engines 1 Figure 262 TNV94 106 model engines 1 Figure 263 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 Improper use or misuse of the E ECU may...

Page 365: ...he key on the fuel injection pump shaft with the keyway in the fuel injection pump drive gear hub Reinstall the fuel injection pump into the fuel injection pump drive gear and gear housing Reinstall the pump retaining nuts finger tight 5 Reinstall the fuel injection pump drive gear lock washer 2 Figure 265 and nut 1 Figure 265 Do not lubricate the threads of the nut or shaft Hold the crankshaft pu...

Page 366: ...74 If installing a new fuel injection pump Reinstall the timing grid sticker provided with the new fuel injection pump onto the back of the gear case front plate Figure 267 Align the standard mark 1 Figure 267 with the reference mark 2 Figure 267 made on the gear case during disassembly Calculate the difference between the timing index numbers 1 Figure 267 of the fuel injection pump that you remov...

Page 367: ...ing change The above calculated difference indicates that the replacement fuel injection pump is to be installed at 0 5 advanced from the Standard Mark 1 Figure 269 on the timing sticker In this case rotate the top of the fuel injection pump away from the cylinder block until the mark on the outside upper mounting boss 1 Figure 270 of the fuel injection pump aligns with the 0 5 mark on the timing ...

Page 368: ...amaged Reinstall the insulator and intake manifold if previously removed 13 Reinstall the coolant pump V pulley 4 Figure 274 spacer 3 Figure 274 if equipped and engine coolant fan 2 Figure 274 14 Reinstall the cooling fan V belt 1 Figure 274 Adjust it as described in Check and adjust Cooling Fan V belt on page 5 21 15 Reinstall the cooling fan guard if equipped 16 Prime the fuel system See on page...

Page 369: ... fuel injection pump housing 1 Figure 275 Treat this number as though there is a decimal point between the two digits i e 68 6 8 2 The engine model number of this machine is 4TNV98 EPDBW The FIR number for this engine is 4 Fuel Injection Pump Timing Index Number X 2 FIR Number FIT Fuel injection Timing in Degrees 6 8 X 2 13 6 4 17 6 Fuel injection Timing Record the calculated fuel injection timing...

Page 370: ...adapter and clamp into the pump plunger opening NOTE Use the M16 adapter used on the MP4 fuel injection pumps and plunger adapter clamp 1 Figure 279 5 Install a dial indicator 1 Figure 280 Mitutoyo or equivalent with a 30 mm extension into the adapter Secure with the plunger adapter clamp 1 Figure 279 at approximately the mid point of its travel NOTE Note The following references to the direction ...

Page 371: ...nformation on the identification of the timing marks NOTE The TDC Top Dead Center mark can be identified by the cylinder numbers stamped near the TDC mark on the flywheel If you are uncertain as to the timing degree designation of the timing marks on the flywheel timing grid you can determine the timing degree designation by measuring the timing grid First measure the distance between two of the l...

Page 372: ...ming Specification on page 7 26 10 Rotate the crankshaft counter clockwise until the dial indicator shows that the injection pump plunger is at the bottom of its stroke Rock the crankshaft back and forth slightly to confirm a point where the dial indicator shows no movement Zero the dial indicator 11 Slowly rotate the crankshaft clockwise until the dial indicator shows a pump plunger lift of 2 5 m...

Page 373: ... bracket s on the fuel injection pump NOTE Loosening the high pressure injection line nuts on the fuel injection pump may make rotating the pump easier 5 Rotate the fuel injection pump until the dial indicator reads 2 5 mm 0 098 in 6 To advance the injection timing rotate the top of the fuel injection pump away from the engine 7 To retard the injection timing rotate the top of the fuel injection p...

Page 374: ...he cylinder head Discard both items 7 Repeat steps to remove the remaining fuel injectors Testing of Fuel Injectors 1 Thoroughly clean the fuel injector nozzle using clean diesel fuel and a brass wire brush 2 Visually inspect the fuel injectors and nozzle protectors for deposits or damage Clean repair or replace as necessary NOTE Test the fuel injector using an injection nozzle tester Operate the ...

Page 375: ...ozzle 6 Pump the operating lever more rapidly to repeatedly pop the injector and observe the spray pattern The pattern should be a very fine uniform spray Figure 290 If a dripping or an uneven pattern is seen Figure 291 service or replace the injector If the fuel injector fails any of these tests it should be serviced or replaced as necessary If the pressure is outside specified limits adjust the ...

Page 376: ...SP001693 Engine Page 196 FG009005 Figure 291 ...

Page 377: ...s 2 Figure 292 between the valve stop spacer and nozzle body for nicks or scratches Check the contact area between the valve stop spacer and the nozzle valve 1 Figure 292 for scoring or pitting Use a magnifier glass to inspect the area 7 Perform a nozzle valve slide test A Wash nozzle body and valve in clean diesel fuel B While holding the nozzle body vertical pull the nozzle valve about 2 3 of th...

Page 378: ...97 2 Remove or add adjusting shims as needed 3 Reassemble the fuel injector assembly Reassembly of Fuel Injectors on page 1 199 4 Retest the fuel injector See Testing of Fuel Injectors on page 194 If the injector cannot be adjusted to the appropriate pressure discard the fuel injector Figure 294 Reference Number Description 1 Fuel Return Passage 2 Injector ID Location 3 Injector Body 4 Pressure Ad...

Page 379: ...etaining bolts 2 Figure 295 to specification 5 Reinstall the fuel injector return line assembly using new gaskets on each side of the injector line screws 6 Reinstall the fuel high pressure fuel lines to each injector and tighten the nuts using a line or flare nut wrench 7 Prime the fuel system See Priming the Fuel System on page 40 8 Operate the engine and check for fuel and coolant leaks Fuel In...

Page 380: ...th or serious injury HAOA050L Figure 298 WARNING Burn Hazard Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury FG009148 Figure 299 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...

Page 381: ...t engine oil to avoid being burned Always wear eye protection Failure to comply could result in death or serious injury FG009152 Figure 302 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 mo...

Page 382: ...cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant CAUTION 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 Be sure to use the spec...

Page 383: ... 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 Number Description 1 Cylinder Head 2 Thermostat 3 Engine Coolant Pump 4 Radiator 5 Coolant Recovery Tank 6 Engine Oil Cooler 7 Cylinder Block Reference Number Description ...

Page 384: ...scription 1 Thermostat Cover 2 Thermostat Cover Gasket 3 Thermostat 4 Thermostat O Ring 5 Special O Ring 6 Engine Coolant Pump 7 Temperature Switch 8 Gasket 9 Engine Coolant Pump Gasket 10 V Belt 11 Engine Coolant Pump V Pulley 12 Spacer 13 Engine Coolant Fan Reference Number Description ...

Page 385: ...l noise sticking excessive play and water leakage Replace the coolant pump if any of these conditions are present 1 Before removing the engine coolant pump or thermostat it will be necessary to drain the engine coolant Drain the coolant into a clean container if the coolant is to be reused Otherwise properly dispose of the coolant 2 Remove the radiator cap 1 Figure 307 3 Remove the drain plug or o...

Page 386: ...way from the engine and out of the way 6 Remove the engine coolant fan guard if equipped engine coolant fan 1 Figure 311 spacer 2 Figure 311 and engine coolant pump V pulley 3 Figure 311 7 Disconnect the coolant hoses and the temperature switch lead wire from the engine coolant pump 8 Remove the engine coolant pump 4 Figure 311 Discard the gasket Figure 308 Figure 309 FG009155 Figure 310 CAUTION P...

Page 387: ...ernal heat source 4 The temperature switch is operating properly if the continuity light or ohmmeter indicates continuity when the fluid temperature reaches 225 F 235 F 107 C 113 C Water Temperature Sensor 1 Inspect the water temperature sensor to make ure that it is properly operating As shown in the following figure connect an electric resistor to the coupler of the water temperature sensor 1 Fi...

Page 388: ... the radiator cap 1 Figure 315 on a cooling system tester 2 Apply 10 8 14 8 psi 75 105 kPa 0 75 1 05 kgf cm2 to the radiator cap The radiator cap relief valve must open within the specified range Reassembly of Engine Coolant Pump 1 Reinstall the thermostat 1 Figure 317 and a new O ring 2 Reinstall the thermostat cover 2 Figure 317 and a new gasket Tighten the thermostat cover bolts 3 Reinstall the...

Page 389: ... drain cock in the radiator Reinstall and tighten the engine block drain plug or reconnect the coolant hose at the oil cooler 8 Fill the radiator and engine with engine coolant See Adjust Intake Exhaust Valve Clearance on page 86 CAUTION Use a new special O ring between the engine coolant pump and the joint Be sure to use the special O ring for each engine model Although the O ring dimensions are ...

Page 390: ...tating parts Failure to comply could result in death or serious injury HAOA050L Figure 321 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 These surfaces are extremely hot while the engine is operating and could seriously burn...

Page 391: ...bly CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap Never mix different types of engine oil This may adversely affect the lubricating properties...

Page 392: ...otor to Inner Rotor Tip Clearance Standard Limit Reference Page 0 0063 in 0 16 mm Outer Rotor to Inner Rotor Tip Clearance on page 9 11 Inner Rotor and Gear Boss Clearance Item Parts Standard Dimension Standard Clearance Standard Clearance Limit Reference Page Inside Clearance of Inner Rotor Gear Boss Diameter 2 0886 2 0925 in 53 05 53 15 mm 0 012 0 020 in 0 3 0 5 mm 0 024 in 0 6 mm Check Rotor Sh...

Page 393: ...Tappet Cam Face Rocker Arm Rocker Arm Bearing Piston Cooling Nozzles Camshaft Bearing Crank Pin Crank Journal Oil Suction Pipe Strainer Pressure Regulator Valve Oil Pump Idle Gear Shaft Cylinder Body Main Gallery Fuel Injection Pump Oil Pressure Switch Turbocharger Oil Filter Bypass Valve Oil Cooler FG009029 Figure 324 ...

Page 394: ...n instrument panel If the mechanical oil pressure test gauge indicates low oil pressure troubleshoot the lubrication system to locate the cause of the low oil pressure Trochoid Oil Pump 4TNV98 Oil Pump Components The oil pump on these model engines is located in the front gear case and is driven by the same gear train that drives the camshaft and fuel injection pump You must remove the front gear ...

Page 395: ...gulator and oil pump cavity Inspect for wear or damage Replace as necessary Check Outer Rotor Outside Clearance Determine the outside clearance of the outer rotor Insert a feeler gauge between the outer rotor 1 Figure 329 and gear case oil pump cavity 2 Figure 329 Record the measurement s and see Check Outer Rotor Outside Clearance on page 9 11 for the service limits Figure 327 Figure 328 CAUTION ...

Page 396: ...s Check Outer Rotor Side Clearance Determine the side clearance of the outer rotor across the pump cavity Measure the depression using a depth micrometer 1 Figure 331 Record the measurement s and see Check Outer Rotor Side Clearance on page 9 12 for the service limits Check Rotor Shaft Clearance Determine the rotor shaft clearance Measure the outside diameter of the rotor shaft 1 Figure 332 and th...

Page 397: ...ump assembly 1 Figure 334 into the gear case housing 2 Figure 334 Tighten the bolts to specified torque 4 Reinstall the gear case cover and crankshaft pulley See Installation of Gear Case Cover on page 156 5 Reinstall the engine coolant pump V pulley 1 Figure 335 spacer 2 Figure 335 engine cooling fan 3 Figure 335 and engine cooling fan guard if equipped 6 Reinstall the V belt Tighten the V belt t...

Page 398: ...ay from moving rotating parts Failure to comply could result in death or serious injury FG009151 Figure 337 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 Failure to comply...

Page 399: ...total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated on the wiring diagram The starter motor will malfunction or break down if the resistance is higher than the specified value CAUTION The starter motor is water proofed according to JIS D 0203 R2 which protects the motor from rain or general cleaning Do not use high pressu...

Page 400: ... Clutch System Overrunning Pinion Projection Voltage at 212 F 100 C 8 6 V max Pinion DP or Module Number of Teeth M3 9 Difference O ring Oil Seal Dry none Application Standard Brush Spring Force 7 868 lbf 35 N 3 6 kgf Height Standard 0 591 in 15 mm Limit 0 354 in 9 mm Magnetic Switch Series Coil Resistance 0 27 W at 68 F 20 C Shunt Coil Resistance 0 60 W at 68 F 20 C Commutator Outside Diameter St...

Page 401: ...harge or replace battery Clean terminals Replace engine oil Repair or replace starter motor Charge or replace battery Clean terminals Inspect wiring up to magnetic switch and repair if nessary Key switch Safety relay Magnetic switch assembly Electrical connections Adjust pinion projection length Inspect shift lever for deformation return spring for fatigue and pinion for sliding Repair meshing bet...

Page 402: ...pring 6 Pinion Stop 7 Retaining Ring 8 Gear Housing 9 Shift Lever 10 Torsion Spring 11 Plunger 12 Dust Covers Shims 13 Magnetic Switch Assembly Solenoid 14 Cover 15 M6 Bolts 2 used 16 Armature Assembly 17 Field Coil Assembly 18 Positive Brushes 19 Negative Brushes 20 Brush Holder Assembly 21 Rear Cover 22 M5 Through Bolts 2 used 23 M4 Bolts 2 used Reference Number Description ...

Page 403: ...unting bolts 1 Figure 343 Remove the starter motor from the flywheel housing Disassembly of Starter Motor 1 Loosen the M8 nut from the magnetic switch solenoid assembly Figure 344 Disconnect the wire from the magnetic switch FG009151 Figure 342 WARNING Shock Hazard Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the elec...

Page 404: ... brush spring into contact with the side of the brush for lifting from the commutator surface On the positive side remove the brush from the brush holder assembly 1 Figure 346 5 Remove the brush holder assembly 1 Figure 347 from the armature assembly 3 Figure 347 6 Pull the armature assembly 3 Figure 347 out from the field coil assembly 2 Figure 347 7 Remove the two M6 bolts 1 Figure 348 retaining...

Page 405: ...sing Remove the bearing retainer assembly from the gear housing 10 Remove the pinion clutch assembly 3 Figure 350 from the bearing retainer assembly 11 Using a flat blade screwdriver remove the retaining ring 1 Figure 351 from the shaft of the pinion 12 Disassemble the pinion stop 3 Figure 352 return spring 4 Figure 352 pinion clutch assembly 1 Figure 352 and pinion shaft 5 Figure 352 Figure 349 F...

Page 406: ...ifications on page 220 for the service limit Measure Commutator Insulation Depth Measure the depth of the insulating material 1 Figure 355 between commutator segments 2 Figure 355 If the depth measures less than the limit use a hacksaw blade 3 Figure 355 to remove the insulating material until the depth is within the limit A normal commutator condition is indicated in 4 Figure 355 An abnormal comm...

Page 407: ...between a commutator segment and the shaft or armature using a multimeter Figure 357 The multimeter should not indicate continuity If the multimeter indicates continuity replace the armature Measure Armature and Commutator Run Outs Measure the armature core run out and the commutator run out using a dial indicator Figure 358 Replace the armature if either of the measurements is less than the limit...

Page 408: ...embly Field Coil Insulation Test Check for continuity between the field coil terminal and the yoke using a multimeter Figure 360 The multimeter should not indicate continuity If the multimeter indicates continuity replace the field coil assembly Measure Brush Length Measure the length of the brush Figure 361 Replace the brush if the length is less than the limit See Starter Motor Specifications on...

Page 409: ...ntinuity Test Check for continuity between the S and M terminals using a multimeter Figure 363 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the magnetic switch Coil Resistance Test See Starter Motor Specifications on page 220 for the service limit Contact Continuity Test Depress the plunger at the bottom of the magnetic switch Check for continuit...

Page 410: ...t Slide the pinion clutch assembly on the shaft It should slide smoothly on the shaft Figure 366 Rust too much grease or damage could prevent the pinion clutch from sliding smoothly If the pinion clutch assembly does not slide smoothly clean the shaft and pinion clutch assembly or replace the damaged component Ball Bearing Inspection Rotate each ball bearing while holding the pinion clutch assembl...

Page 411: ...the gear housing Reinstall and tighten the three M4 bolts 4 Apply a small amount of high temperature lithium grease obtain locally to the sliding portions of the shift lever 1 Figure 369 Reassemble the torsion spring 2 Figure 369 shift lever and dust cover s 3 Figure 369 plunger 4 Figure 369 and magnetic switch assembly 5 Figure 369 5 Reassemble the magnetic switch assembly to the gear housing Pry...

Page 412: ...older assembly to the armature assembly 10 Reinstall the field coil assembly with the armature assembly to the gear housing 11 Reinstall the rear cover to the brush holder assembly Securely tighten the two bolts 12 Reinstall the two M4 through bolts Figure 373 Securely tighten the through bolts Reconnect the wire to the magnetic switch assembly Tighten the M8 nut Reinstall the cover over the conne...

Page 413: ...the switch ON and measure the pinion moving distance L in the thrust direction Figure 374 Perform this test within 10 seconds See Starter Motor Specifications on page 220 for the service limit 5 If the measured Ldimension is outside the standard range adjust the dust covers to obtain the standard range Dust cover 1 Figure 375 are available in 0 020 in 0 5 mm and 0 031 in 90 8 mm thicknesses FG0090...

Page 414: ...on the starter motor 5 Install a switch 6 Figure 376 in a circuit between the battery positive terminal 2 Figure 376 and the starter magnetic switch solenoid terminal 8 Figure 376 on the starter motor 6 Use a suitable tachometer to monitor the rpm of the starter 7 Turn the switch to the ON position Monitor the rpm amperage draw and voltage For test specifications for the appropriate starter motor ...

Page 415: ...or serious injury FG009151 Figure 379 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 Failure to comply could result in death or serious injury HAOA050L Figure 380 WARNING B...

Page 416: ...ry FG009152 Figure 382 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 FG009155 Figure 383 CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block whil...

Page 417: ...butor for additional training 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 Damage to the alternator will result CAUTION Do not remove the positive battery cable from alternator terminal B while the engine is operating Damage to the alternator will result...

Page 418: ...faintly during normal operation CAUTION Using a non specified V belt will cause inadequate charging and shorten the belt life Use the specified belt CAUTION 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...

Page 419: ... Rating Continuous Battery Voltage 12 Volts Rated Revolution 5 000 rpm min 1 Operating Range 1 350 18 000 rpm min 1 Grounding Characteristics Negative Side of Circuit Integrated Regulator IC Regulator Outside Diameter of Pulley 2 724 in 69 2 mm Belt Shape Type A Nominal Output 13 5 Volts Heat 20 Amps Weight 3 97 lb 1 8 kg Revolution Direction As Viewed From Pulley Clockwise Rating Continuous Batte...

Page 420: ... Inspect a lternator Inspect diode positive side Battery indicator ON Battery indicator flashes Batter indicator is di m Battery indicator is di m Battery voltage greater than 15 5 volts Battery voltage is between 13 and 15 volts With en gine id ling measure voltage at L terminal and at battery With en gine id ling turn light switch ON Battery voltage minus L ter minal voltage is greater than 0 5 ...

Page 421: ...SP001693 Page 241 Engine ...

Page 422: ...rnator 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 ...

Page 423: ...9 Bearing Cover Bolt 4 used 10 Rotor Assembly 11 Rear Frame Housing Bearing 12 Bearing Cover 13 Thrust Washer 14 Thrust Washer 15 Nut 2 used 16 Nut 17 Insulation Bushing 18 Spring 2 used 19 Brush Holder 20 Rear Frame Housing 21 Bolt 2 used 22 Holder 23 IC Regulator Assembly 24 Bolt 2 used 25 Bolt 26 Brush 2 used 27 Bolt 28 Rear Cover 29 Bolt 3 used Reference Number Description ...

Page 424: ...sembly 6 IC Regulator Assembly Reference Number Description 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 Damage to the alternator will result CAUTION Do not remove the positive battery cable from alternator terminal B while the engine is operating Damage...

Page 425: ...Page 245 Engine Alternator Standard Output 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 STANDAED CHAEACTERISTICS 13 5V CONTANT AMBIENT TEMP 25 C A OUTPUT CURRENT ALTERNATOR SPEED X10 min Hot Cold FG008440 3 1 Figure 387 ...

Page 426: ...NG 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 Failure to comply could result in death or serious injury CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder...

Page 427: ...sh springs 4 Figure 391 and brushes 5 Figure 391 4 Remove the bolt retaining the regulator assembly 1 Figure 392 to the holder 2 Figure 392 5 Remove the bolts retaining the holder 2 Figure 392 to the rear frame housing Remove the holder 6 Remove the nut 3 Figure 392 retaining the insulation bushing 4 Figure 392 Remove the insulation bushing 7 Remove the two bolts 1 Figure 393 and two nuts 2 Figure...

Page 428: ...place 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 Remove the plate Use a puller to remove the bearing Discard the bearing 11 If it is necessary to replace the bearing 1 Figure 396 in the rear frame housing use a puller to remove Discard the bearing Remove the bearing cover 2 Figure 396 and two thr...

Page 429: ... Press the bearing 2 Figure 398 into the front frame housing Reinstall the plate 4 Figure 398 to the front housing Tighten the four bolts 3 Figure 398 3 Position the stator assembly 1 Figure 398 on the front frame housing studs 4 Lubricate the shaft of the rotor assembly 1 Figure 399 Press the rotor assembly into the front frame housing 2 Figure 399 and rear frame housing 3 Figure 399 5 Align the ...

Page 430: ...he brush holder 3 Figure 402 springs 4 Figure 402 and brushes 5 Figure 402 9 Reattach the regulator assembly and holder to the rear frame housing 10 Reinstall the rear cover 2 Figure 402 to the rear frame housing with three bolts 1 Figure 402 11 Reassemble the pulley 2 Figure 403 and nut 1 Figure 403 to the shaft of the rotor assembly Tighten the nut Figure 401 Figure 402 Figure 403 ...

Page 431: ...0 in lb 1 7 2 3 N m 17 23 kgf m 3 Reinstall the V belt Tighten the V belt to the proper tension as described in See on page 70 4 Start the engine Listen for any unusual sounds from the alternator 5 Verify that the charge indicator is ON while the engine is operating If the charge indicator is not ON repair the problem before operating the engine Figure 404 CAUTION Do not operate the engine if the ...

Page 432: ...ecific part detail see the Parts Catalog for the engine you are working on Figure 405 Reference Number Description 1 Rear Cover 2 Nut 3 Lock Washer 4 Flat Washer 5 Rear Bearing 6 Output Wire and Connector 7 Plate 8 Spacer 9 Stator Assembly 10 Front Bearing 2 used 11 Flat Washer 12 Flywheel Assembly 13 Pulley Half 14 Through Bolt Reference Number Description ...

Page 433: ...ch is rotated via the engine cooling fan drive belt The resultant output is an AC alternating current signal The AC is converted to DC direct current in the IC Regulator The IC Regulator outputs charging DC current to the battery 1 2 3 4 5 6 FG009112 Figure 406 Reference Number Description 1 Dynamo 2 IC Regulator Assembly 3 Key Switch 4 Charge Lamp 3 4 Watts Max 5 Battery 6 Load Reference Number D...

Page 434: ...SP001693 Engine Page 254 Dynamo Standard Output 1 2 3 4 5 6 7x10 0 5 10 15 20 25 3 STANDARD CHARACTERISTICS 12V OUTPUT CURRENT A ALTERNATOR SPEED min 1 FG009113 Figure 407 ...

Page 435: ...uity between each stator wire terminal and engine ground NOTE The meter reading should infinity If the meter reading indicates continuity the windings are shorted to ground and the stator must be replaced Testing Dynamo Regulated Output 1 Test and record the battery voltage with the engine not running 2 Start the engine and operate it at normal operating rpm 3 Again check the battery voltage with ...

Page 436: ...ove the nut 2 Figure 408 from the gear case stud Remove the dynamo Disassembly of Dynamo 1 Remove the rear cover 1 Figure 409 2 Remove the nut 2 Figure 409 lock washer 3 Figure 409 and flat washer 4 Figure 409 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 Figure 408 Figure 409 ...

Page 437: ... and the stator assembly 2 Figure 411 5 Remove the rear bearing 3 Figure 411 Reassembly of Dynamo 1 Reinstall the rear bearing 3 Figure 412 2 Reinstall the stator 2 Figure 412 and screws 3 Reinstall the front bearings 5 Figure 413 and spacer 6 Figure 413 4 Reinstall the flat washer 4 Figure 413 flywheel 3 Figure 413 pulley half 2 Figure 413 and through bolt 1 Figure 413 Figure 410 Figure 411 Figur...

Page 438: ...t adjuster bolt 1 Figure 415 2 Reconnect the dynamo output wire connector 3 Reinstall the V belt Tighten the V belt to the proper tension as described in See on page 70 4 Start the engine Listen for any unusual sounds from the alternator 5 Verify that the charge indicator is ON while the engine is operating If the charge indicator is not ON repair the problem before operating the engine Figure 414...

Page 439: ...ver if an LED is used in the battery indicator the LED will shine faintly during normal operation CAUTION 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 The starter motor will malfunction and fail if the re...

Page 440: ...N 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 AWG Metric Nominal mm2 Ohms Foot Resistance 20 0 5 0 009967 18 0 8 0 006340 16 1 25 0 004359 14 2 0 002685 12 3 0 001704 10 5 0 001073 8 8 0 000707 6 15 0 000421 4 20 0 000270 ...

Page 441: ...n 0 002 Ω For starter motors of greater than 2 68 HP 2 kW the total resistance must be less than 0 0012 Ω AWG mm2 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 m ft m ft 6 15 1 5 4 75 N A N A 4 20 2 3 7 4 N A N A 2 30 3 8 12 6 2 3 7 5 1 40 4 6 15 3 2 8 9 2 0 1 0 50 5 9 19 5 3 5 11 6 00 2 0 60 7 0 22 8 4 ...

Page 442: ... 3 0 4 0 4 0 4 0 60 6 4 4 2 2 1 0 2 0 3 0 3 0 4 0 4 0 4 0 70 6 4 2 2 1 0 2 0 3 0 4 0 4 0 80 6 4 2 2 1 0 3 0 3 0 4 0 4 0 90 4 2 2 1 0 2 0 3 0 4 0 4 0 100 4 2 2 1 0 2 0 3 0 4 0 24 Volts 5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 8 10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6 15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 2 20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2 25 12 12 10 10 8 6 6...

Page 443: ... 412 20 0 812 0 519 19 0 992 0 653 18 1 024 0 823 17 1 15 1 04 16 1 29 1 31 15 1 45 1 65 14 1 63 2 08 13 1 83 2 63 12 2 05 3 31 11 2 30 4 15 10 2 59 5 27 9 2 91 6 62 8 3 26 8 35 7 3 67 10 6 6 4 11 13 3 5 4 62 16 8 4 5 19 21 2 3 5 83 26 7 2 6 54 33 6 1 7 35 42 4 0 1 0 8 25 53 4 00 2 0 9 27 67 5 000 3 0 10 40 85 0 0000 4 0 11 68 107 2 00000 5 0 13 12 135 1 000000 6 0 14 73 170 3 1 1 circular mil CM ...

Page 444: ...001693 Engine Page 264 TROUBLESHOOTING Special Service Tools Compression Gauge Kit For measuring compression pressure Gauge Set Adapter for direct injection 4 valve cylinder head for 4TNV98 Z 165 FG009120 ...

Page 445: ...Warm up the engine 2 Stop the engine Remove the high pressure fuel injection lines as an assembly from the engine Remove the fuel injector from the cylinder to be measured See Removal of Fuel Injectors on page 194 3 Remove the valve cover assembly See Removal of Valve Cover on page 109 Remove the fuel injector from the cylinder to be tested See Removal of Fuel Injectors on page 194 4 Turn off the ...

Page 446: ...mp stop solenoid 11 Prime the fuel system Check for leaks Test the engine Standard Compression Pressure Reference Value Engine Speed and Compression Pressure Use for Reference Figure 417 Engine Model Compression Pressure at 250 rpm 250 min 1 Deviation Between Cylinders Standard Limit 4TNV98 E 483 513 psi 3 33 3 53 MPa 34 36 kgf cm2 384 414 psi 2 65 2 85 MPa 27 29 kgf cm2 29 43 psi 0 2 0 3 MPa 2 3 ...

Page 447: ... 2 Valve Clearance Excessive or no clearance Adjust the valve clearance 3 Valve Timing Incorrect valve clearance Adjust the valve clearance 4 Cylinder Head Gasket Gas leak from gasket Replace the gasket Retighten the cylinder head bolts to the specified torque 5 Intake Exhaust Valve Sticking valve Replace the intake exhaust valve Valve Seat Gas leak due to worn valve seat or foreign matter trapped...

Page 448: ...ce 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 ...

Page 449: ...longer than before to start up engine None slight Remarkable Cannot be set to particular speed Poor acceleration Does not smoothly return to low speed Hunting occurs Hunting occurs Normal White Black White exhaust gas Black exhaust gas Engine system Intake exhaust valves with improper clearances O O O O O O Adjust the valve clearances See Measuring and Adjusting Valve Clearance on page 123 Compres...

Page 450: ...th accelerator stays at a constant speed No load Work load Smoke color High knocking sound at combustion time Uneven combustion sound Abnormal sound other than combustion sound from engine Engine vibrates heavily Too much lubricating oil consumed Lubricating oil diluted with fuel Lubricating oil mixed with water Oil pressure low oil pressure warning lamp lit Overheat water temperature warning lamp...

Page 451: ...ditions of failure Possible causes Starting failure Engine stall after start up Speed control error Engine output low Noise and vibration Lubricating oil Cooling water Intake air Exhaust gas Fuel Electrical parts Corrective Action Referenced page number Starterdoes not rotates Starter rotates Smoke Revolution speed cannot be changed with accelerator stays at a constant speed No load Work load Smok...

Page 452: ...O O O O Repair or replace the fuel injection pump Monitor the rack actuator using the diagnosis tool ECU failure lamp disconnected O Replace the lamp ECU faulty ECU self diagnosis failure O O O O O Replace the ECU Symptoms and conditions of failure Possible causes Starting failure Engine stall after start up Speed control error Engine output low Noise and vibration Lubricating oil Cooling water In...

Page 453: ... conditions of failure Possible causes Starting failure Engine stall after start up Speed control error Engine output low Noise and vibration Lubricating oil Cooling water Intake air Exhaust gas Fuel Electrical parts Corrective Action Referenced page number Starterdoes not rotates Starter rotates Smoke Revolution speed cannot be changed with accelerator stays at a constant speed No load Work load ...

Page 454: ...5 1 5sec 128300 77920 YAZAKI NO 7122 2046 YAZAKI NO 7123 2249 PRE HEAT LAMP AFTER 15sec OFF LESS THAN 3 4W AIR HEATER DC12V 400W 129120 77501 LA206 SAFETY RELAY 119802 77200 SUMITOMO NO 6195 0060 SUMITOMO NO 6195 0021 SUMITOMO NO 6195 0057 SUMITOMO NO 6195 0024 GROUND SHOULD BE CONNECTED TO BATTERY DIRECTLY EMERGENCY STOP SWITCH DETAIL A YAZAKI NO 7123 2228 YAZAKE NO 7123 2237 00 YAZAKE NO 7122 22...

Page 455: ...SP001627 Page 1 Drive Coupling Main Pump SP001627 DRIVE COUPLING MAIN PUMP SP001627 Drive Coupling Main Pump Edition 1 ...

Page 456: ...SP001627 Drive Coupling Main Pump Page 2 MEMO ...

Page 457: ...SP001627 Page 3 Drive Coupling Main Pump Table of Contents Drive Coupling Main Pump Safety Precautions 5 Applicable Models 5 Drive Coupling 6 Installation of Drive Coupling 7 Installation Procedure 7 ...

Page 458: ...SP001627 Drive Coupling Main Pump Page 4 MEMO ...

Page 459: ...N 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 460: ...RIVE COUPLING Figure 1 show typical drive coupling installations ENGINE 7 9 6 5 3 2 4 1 8 FG013229 Figure 1 Reference Number Description 1 Coupling 2 Washer 3 Bolt 4 Pump Cover 5 Washer 6 Bolt 7 Pump 8 Washer 9 Bolt Reference Number Description ...

Page 461: ...ng 1 Figure 1 in the engine flywheel with spring washers 2 Figure 1 and bolts 3 Figure 1 NOTE Apply lock tight to bolts NOTE Tightening torque 13 8 kg m 2 Assemble the pump cover 4 Figure 1 to the fly whell housing with spring washers 5 Figure 1 and bolts 6 Figure 1 NOTE Check the distance between the coupling and the pump cover to be 9 mm NOTE Tightening torque 6 5 kg m 3 Assemble the pump 7 Figu...

Page 462: ...SP001627 Drive Coupling Main Pump Page 8 ...

Page 463: ...1Hydraulics ...

Page 464: ......

Page 465: ...SP000028 Page 1 Accumulator SP000028 ACCUMULATOR SP000028 Accumulator Edition 1 ...

Page 466: ...SP000028 Accumulator Page 2 MEMO ...

Page 467: ...SP000028 Page 3 Accumulator Table of Contents Accumulator Safety Precautions 5 Applicable Models 5 General Description 6 Specifications 8 ...

Page 468: ...SP000028 Accumulator Page 4 MEMO ...

Page 469: ...ools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling the load Remember that ultimate safety is your own personal responsibility 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 DX255LC 5001 and Up DX300LC 5001 a...

Page 470: ... they are as follows 1 With no gas charge in the upper chamber 0 bar 0 psi empty and no oil in the bottom 0 bar 0 psi dry the elastic diaphragm hangs loosely 2 When the prepressure charge of gas usually nitrogen is introduced through the port at the top of the accumulator the diaphragm expands to maximum size The valve button in the center of the diaphragm pushes into the fluid opening in the bott...

Page 471: ...ble diaphragm begins to retract upward 4 When system oil is at highest working pressure and the accumulator fills to maximum reserve capacity the flexible diaphragm is pushed up into the top of the upper chamber The highest working pressure is sometimes referred to as the P3 pressure and can also be referenced on the manufacturer s data label on the exterior of the accumulator 5 If system oil pres...

Page 472: ...cc 19 53 in3 DX180LC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX225LC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX225NLC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX255LC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX300LC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 in3 DX340LC S N 5001 and Up Pilot 10 kg cm2 140 psi 320 cc 19 53 ...

Page 473: ...SP001628 Page 1 Center Joint Swivel SP001628 CENTER JOINT SWIVEL SP001628 Center Joint Swivel Edition 1 ...

Page 474: ...SP001628 Center Joint Swivel Page 2 MEMO ...

Page 475: ...1628 Page 3 Center Joint Swivel 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 ...

Page 476: ...SP001628 Center Joint Swivel Page 4 MEMO ...

Page 477: ... 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up ...

Page 478: ...able of allowing continuous 360 rotation of the upper structure in relationship to the lower structure Disassembly Diagram 6 1 4 3 14 15 10 7 12 13 2 8 11 9 5 FG013233 Figure 1 Reference Number Description 1 Hub 2 Shaft Assembly 3 Cover 4 Spacer 5 Shim 6 Shim 7 Seal Dust 8 Sliper Seal 9 O ring 10 O ring 11 Retaining Ring 12 Plug 13 Plug 14 HEX Bolt 15 Spring Washer Reference Number Description ...

Page 479: ...ng the Shaft assembly tightening at least 2 10 mm eye bolts on the Hub and lifting it with a hoist slowly 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 M10 Bolt...

Page 480: ...als with new ones for they cannot be reused FG013236 Figure 4 CAUTION Care should be taken not to damage the inside of the Hub because is likely to be damaged when disassembling the slipper seal It may be disassembled more easily with a driver whose tip is bent as shown in the figure below PT 1 4 6 mm wrench PT 3 8 8 mm wrench FG013238 Figure 5 CAUTION The inside of the Hub should be air washed an...

Page 481: ... moving part before assembly to reduce any assembly friction as much as possible FG013239 Figure 6 PT 1 4 6 mm wrench PT 3 8 8 mm wrench Engagement torque 3 4 kg m Engagement torque 6 7 kg m CAUTION Apply active oil to every funcational moving part before assembly to reduce any assembly friction as much as possible CAUTION For any sliper seal which is protruded press it with finger to seat it in i...

Page 482: ...its place and assemble the cover in the direction as shown in the figure 9 Engage the cover bolt M10 at torque of 5 6 kg m FG013241 A C F P Figure 7 CAUTION Applying active oil to the surface of the shaft enables the assembly without any damage to the sliper seal CAUTION Tap the Hub in a zigzag pattern that it does not tilt to one side FG013242 Figure 8 CAUTION After the completion of the assembly...

Page 483: ...SP001628 Page 11 Center Joint Swivel CENTER JOINT ASSEMBLY FG013245 Figure 9 ...

Page 484: ...SP001628 Center Joint Swivel Page 12 ...

Page 485: ...SP001629 Page 1 Cylinders SP001629 CYLINDERS SP001629 Cylinders Edition 1 ...

Page 486: ...SP001629 Cylinders Page 2 MEMO ...

Page 487: ...cautions 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 19 Slipper Seal Jig 20 Slipper Seal Straightening Jig 21 Disassembly 22 Assembly 28 ...

Page 488: ...SP001629 Cylinders Page 4 MEMO ...

Page 489: ... 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 490: ...front of the cylinder oil path B The cylinder rod is extended as oil flow is pumped through the circuit to the back side of the piston The force F1 of the piston stroke can be expressed by the formula below where P circuit oil pressure and the inside diameter of the cylinder is expressed by B Figure 1 P Pressure p 3 14 B Cylinder Inside Diameter When the cylinder rod is retracted oil flow through ...

Page 491: ... 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 Q1 Q2 Figure 3 Q1 S x π B2 4 Q2 S x π B2 R2 4 ...

Page 492: ...fer 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 Boom Cylinder 17 18 15 19 16 23 22 21 12 12 11 9 10 1 2 24 7 8 6 13 13 13 14 3 4 20 5 24 FG011071 Figure 4 ...

Page 493: ...sh 5 Rod Cover 6 DD bush 7 Ring Retaining 8 Seal Buffer 9 U packing 10 Wiper Dust 11 Ring Retaining 12 O ring 13 Ring Back Up 14 O ring 15 Ring Cushion 16 Piston 17 Ring Glyd 18 Ring Wear 19 Ring Dust 20 O ring 21 Ring Back Up 22 Nut Piston 23 Screw Set 24 Nipple Grease Reference Number Description ...

Page 494: ...SP001629 Cylinders Page 10 Arm Cylinder A B A 4 3 13 13 14 6 5 12 13 12 7 1 2 17 16 15 21 20 18 19 19 22 23 30 B 25 24 26 27 28 29 11 9 8 10 FG011072 Figure 5 ...

Page 495: ...l Buffer 9 U packing 10 Wiper Dust 11 Ring Retaining 12 O ring 13 Ring Back Up 14 O ring 15 Ring Cushion 16 Piston 17 Ring Glyd 18 Ring Wear 19 Ring Dust 20 O ring 21 Ring Back Up 22 Nut Piston 23 Screw Set 24 Plunger Cushion 25 Ring Stop 26 Valve Check 27 Spring 28 Support Spring 29 Plug Hex Socket 30 Nipple Grease Reference Number Description ...

Page 496: ...SP001629 Cylinders Page 12 Bucket Cylinder 4 23 11 10 9 5 3 7 8 14 12 13 19 20 15 18 16 1 2 17 18 21 23 6 A A B B 22 FG011073 Figure 6 ...

Page 497: ...bly 4 Bush 5 Rod Cover 6 DD bush 7 Ring Retaining 8 Seal Buffer 9 U packing 10 Wiper Dust 11 Ring Retaining 12 O ring 13 Ring Back Up 14 O ring 15 Piston 16 Ring Glyd 17 Ring Wear 18 Ring Dust 19 O ring 20 Ring Back Up 21 Nut Piston 22 Screw Set 23 Nipple Grease Reference Number Description ...

Page 498: ...SP001629 Cylinders Page 14 Boom Swing Cylinder B B A A 10 8 7 9 5 6 17 17 19 20 21 14 15 13 12 16 18 3 2 11 22 22 4 FG013247 Figure 7 ...

Page 499: ... 3 Rod Assembly 4 Bush 5 Rod Cover 6 DU bush 7 U packing 8 Ring Back Up 9 Wiper Dust 10 Ring Retaining 11 O ring 12 Ring Back Up 13 O ring 14 Washer 15 Piston 16 Ring Glyd 17 Ring Dust 18 Ring Wear 19 O ring 20 Nut Piston 21 Screw Set 22 Nipple Grease Reference Number Description ...

Page 500: ...C 0 2 0 1 0 2 0 1 R R15 R20 C3 C5 35 350 ARS4730L 15 4 R 0 5 Through Hole 8 Figure 8 Model Cylinder øA mm øB mm C mm D mm DX60R ARM 106 0 66 0 11 0 4 5 BOOM 112 0 72 0 11 0 4 5 BUCKET 106 0 66 0 11 0 4 5 SWING 109 0 69 0 11 0 4 5 DX80R ARM 114 0 74 0 11 0 4 5 BOOM 119 0 79 0 11 0 4 5 BUCKET 109 0 69 0 11 0 4 5 SWING 112 0 72 0 11 0 4 5 ...

Page 501: ... R F 2 Through Hole 8 15 ARS4740L 4 R5 Figure 9 Model Cylinder øA mm øB mm C mm D mm DX60R ARM 65 0 12 0 22 0 52 0 BOOM 80 0 12 0 25 0 55 0 BUCKET 65 0 12 0 22 0 52 0 SWING 80 0 12 0 25 0 55 0 DX80R ARM 75 0 12 0 27 0 60 0 BOOM 75 0 12 0 27 0 60 0 BUCKET 60 0 12 0 22 0 52 0 SWING 80 0 12 0 25 0 55 0 DOZER 70 0 12 0 25 0 55 0 ...

Page 502: ...e R0 4 20 A 20 5 A F 15 1 B 40 E G ARS4750L B Figure 10 Model Cylinder øA mm øB mm E mm F mm DX60R ARM 50 0 58 0 20 0 5 0 BOOM 50 0 58 0 20 0 5 0 BUCKET 50 0 58 0 20 0 5 0 SWING 50 0 0 0 20 0 0 0 DOZER 65 0 70 0 30 0 0 0 DX80R ARM 65 0 78 0 20 0 6 0 BOOM 65 0 78 0 20 0 6 0 BUCKET H C 50 0 58 0 20 0 5 0 K L 55 0 66 0 20 0 5 5 SWING 65 0 78 0 20 0 6 0 DOZER 50 0 0 0 20 0 0 0 ...

Page 503: ...used DNMG Tip Nose R0 4 D C DIA B 40 15 3 C1 5 DIA B DIA A DIA A 20 R0 2 1 ARS4760L Figure 11 Model Cylinder øA mm øB mm C mm D mm DX60R ARM 53 0 69 0 4 0 7 0 BOOM 58 0 74 0 4 5 7 0 BUCKET 55 0 62 0 4 5 7 0 DOZER 80 0 74 0 4 5 7 0 DX80R ARM 63 0 79 0 5 0 7 0 BOOM 68 0 84 0 4 5 7 0 BUCKET 53 0 69 0 4 5 7 0 SWING 58 0 74 0 4 5 7 0 DOZER 58 0 74 0 4 5 7 0 ...

Page 504: ...g ARS4770L A 2 A A 14 B B 40 5 R 1 0 R1 1 0 Figure 12 Model Cylinder øA mm øB mm DX60R ARM 79 5 11 5 BOOM 104 5 21 5 BUCKET 79 5 15 SWING 109 5 20 5 DOZER 109 5 10 DX80R ARM 99 6 28 BOOM 114 6 26 BUCKET 84 5 28 5 SWING 109 5 21 DOZER 99 6 19 5 ...

Page 505: ...nders Slipper Seal Straightening Jig ARS4780L 2 R1 50 25 100 A 15 A 2 5 R 2 C 1 Figure 13 Model Cylinder øA mm DX60R ARM 85 7 BOOM 105 7 BUCKET 80 7 DOZER 110 7 DX80R ARM 100 7 BOOM 115 7 BUCKET 85 7 SWING 110 7 DOZER 100 7 ...

Page 506: ... or other protective material around piston rod to avoid possibility of accidentally scratching or scoring rod surface while fasteners are being loosened and removed Component parts numbered in parentheses are keyed to Figure 4 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 hydraul...

Page 507: ...nd of cylinder wall before using a plastic or other soft faced hammer for final disassembly 5 Begin withdrawing piston rod assembly away from cylinder Attach a lifting support when final 1 3 of rod is still inside barrel of cylinder Prepare support blocks for piston rod before it has been completely withdrawn 6 Lower piston rod to support blocks and detach wear ring outer surface 18 from end of ro...

Page 508: ...through end of rod 8 Remove set screw by using a socket wrench 9 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 20 HAOF340L Figure 21 Figure 22 ...

Page 509: ...mer to evenly pull off rod cover 9 from end of piston rod Be careful not to damage rod bushing 6 and dust wiper U packing and other seals 12 Use a dull rounded tip tool to pry off O ring 11 and backup ring 12 13 Find a screwdriver with an appropriate width tip to facilitate removal of slipper seal 19 wear ring 18 and slide ring 17 from piston 16 Figure 23 Figure 24 HAOF37OL Figure 25 Figure 26 ...

Page 510: ...ring 21 from cylinder head 15 During disassembly of cylinder head be careful not to damage buffer seal 5 and U packing 4 16 Disassemble retaining ring 3 and dust wiper 2 Separate retaining ring 8 and rod bushing 6 HAOF38OL Figure 27 HAOF39OL Figure 28 Figure 29 ...

Page 511: ...SP001629 Page 27 Cylinders 17 Force out pin bushing 1 from body of cylinder Figure 30 ...

Page 512: ...ts install dust wiper 2 and rod bushing 6 to rod cover 9 Insert retaining rings 3 and 8 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 Prepare the work area ...

Page 513: ...nning of this procedure to attach seal Cool seal by pushing a retracting jig against seal for several minutes Apply a strip of clean see through sealing tape around slipper seal to keep it free of dust 5 Immobilize piston rod on solid support blocks Assemble O ring 20 and backup ring 21 Prepare to attach rod cover assembly to piston rod Push rod cover by tightening piston nut 22 6 Assemble cushion...

Page 514: ...er before assembly 10 Preapply fastener locking compound Loctite 242 or 243 or an alternate manufacturer s equivalent product to all end cover retaining bolts Wrap a protective cushion around end of rod while tightening fasteners to prevent possible damage to polished surface of rod should a wrench slip during retightening Figure 37 Figure 38 Reference Number Description 1 Set Screw Figure 39 Figu...

Page 515: ...SP001630 Page 1 Swing Motor SP001630 SWING MOTOR SP001630 Swing Motor Edition 1 ...

Page 516: ...SP001630 Swing Motor Page 2 MEMO ...

Page 517: ...stallation and Piping 16 Oil Filling 17 Precaution in Starting Operations 17 Troubleshooting 18 General Cautions 18 Investigation Manner of the Motor Body 18 Condition and Countermeasures of Troubles 19 Disassembling and Assembling 21 Tightening Torque of Bolts 21 Necessary Tools 21 Disassembly of Motor 23 Assembly of Motor 28 Disassembly of Reduction Gear 34 Assembly of Reduction Gear 37 Maintena...

Page 518: ...SP001630 Swing Motor Page 4 MEMO ...

Page 519: ...w 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 520: ...CATION OF TYPE TSM 32 CA B RG 250 D 1 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 ...

Page 521: ...ed from 28 98 cc rev to 31 5 cc rev by the change of displacement MODEL TSM32 S CAB RG250D Displacement 31 5 cc rev Set Pressure of Relief Valve 220 kgf cm2 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 cm2 Theoretical Output Torque 205 kgf m Gear Ratio 19 464 Weight 49 7 kgf ...

Page 522: ...F WORKING Construction 40 4 19 20 27 41 42 21 44 26 40 1 43 32 33 34 35 36 37 28 30 31 28 38 27 27 8 7 3 17 16 24 23 14 14 13 12 11 9 10 15 43 22 25 5 29 39 2 18 R9 R17 R20 R8 R7 R22 R18 R19 R21 R12 R14 R16 R11 R13 R15 R10 R1 R4 R5 R3 R6 R2 FG013250 Figure 1 ...

Page 523: ...ng 28 O ring 29 O ring 30 Spool 31 Spring 32 Plunger A 33 Filter 34 Bush 35 Spacer 36 Throttle Plate 37 Spring 38 RO Plug 39 RO Plug 40 Plug 41 Orifice 42 Snap Ring 43 Socket Bolt 44 Relief Valve R1 Gear Casing R2 Pinion Shaft R3 Taper Roller Bearing R4 Taper Roller Bearing R5 Oil Seal R6 Bearing Cover R7 Half Collar R8 Carrier No 2 R9 Carrier No 1 R10 Thrust Washer No 3 R11 Inner Ring No 2 R12 In...

Page 524: ...output shaft During the second half of the motor s revolution low pressure oil is discharged as the pistons ride to toward a higher position on the shoe plate A small amount of supply oil flows through the center of each piston to lubricate the piston ball joint and the piston shoe face The motor is internally lubricated from leakage inside the motor To reverse rotation system oil flow is changed ...

Page 525: ...iply the pressure area A2 by pressure Pg of room g in the plunger 301 Here Pg is the pressure of room g applied pressure by passing oil through orifice m If Pg arrives at the pressure which is determined by spring 321 pushing the piston 302 the piston move to left side when piston 302 move left side room h operates as damping room which is designed at the side of adjustment plug 401 and piston 302...

Page 526: ...SP001630 Swing Motor Page 12 Figure 4 Relief Valve TSR25A Working Description ...

Page 527: ...ned 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 Figure 5 Brake Working Description ...

Page 528: ...tation Direction The relation between the oil flow and the revolutionary direction of the shaft is self explanatory as shown in Figure 6 The revolutionary direction of a motor vary according to the slope surface of casing Pay attention to discriminate between geometry of casing and the direction of flange as the direction of tilting angle External Load of Shaft Pay attention to the shaft of motor ...

Page 529: ...e of 10 to 1 000 cst The range of working temperature is limits to 25 C 100 C because of the oil seal O ring Further the deterioration of the working fluid becomes excessive beyond 65 C therefore it is desirable not to exceed 60 C 20 30 6 7 8 9 10 15 20 25 30 40 50 75 100 150 200 300 400 500 750 1 000 20 10 0 10 20 30 40 50 60 70 80 90 100 110 10 210 0 10 20 30 40 50 60 70 80 90 100 110 120 130 14...

Page 530: ...ness level of class 8 of NAS Also install a 10μ filter in the hydraulic circuit and MILLIPORE FILTER pollution level recommends below 2 4 mg 100 cc Installation and Piping 1 When the motor is installed that its shaft turns downside 2 The motor should be installed that it is concentricity below 0 05 mm 3 The tightening torque of bolts for fixing the motor to the bracket is shown in assembly drawing...

Page 531: ...be removed otherwise it will be likely to be causes of imperfect working or a damage of the motor Precaution in Starting Operations 1 If the direction of revolution is correct or not 2 Whether or not there is any leakage of oil from the motor 3 If the equipment vibrates abnormally or not during operation or when the revolution direction is changed 4 If the oil temperature rises rapidly in spite of...

Page 532: ... handling of O ring gasket Once seals have been disassembled they should be replaced even if damage is not observed Investigation Manner of the Motor Body It is extremely difficult to trace trouble in the hydraulic circuits Inspect the following items and investigation whether or not the fault is caused by the motor 1 Inspection the oil in casing Remove the drain plug and inspect the hydraulic oil...

Page 533: ...rake dose not release 4 Stick of brake piston 5 Stick of friction plate 1 Load removes 2 Do repair or inspect the piston shoe cylinder block valve plate etc 3 1 Do repair or inspect circuit 2 Check for the break valve 3 Assembly and inspection 4 Assembly and inspection Replace for the stick parts Condition Cause Remedy The revolutionary direction is reverse 1 The revolutionary direction of motor i...

Page 534: ...r damaged parts Condition Cause Remedy Motor is much slip 1 Working defectiveness of relief valve is the same item 1 2 Seat defectiveness of plunger 1 It is the same item 1 2 Replace it Condition Cause Remedy Oil leak from the oil seal 1 The lip is dirty or damaged 2 The shaft may be damaged or worn out 3 The lib is damaged too high pressure in the casing 4 The shaft is rusty 1 Replace the oil sea...

Page 535: ...600 100 44 Name Size 2 face width Application Part Tool Hexagon Bolt M12 10 Valve Casing Hexagon spanner socket wrench Plug M20 10 RO Plug Hexagon spanner socket wrench Plug PF 1 8 4 RO Plug Hexagon spanner socket wrench Plug PF 1 4 6 RO Plug Hexagon spanner socket wrench Relief Valve M30 30 Relief Valve Hexagon spanner socket wrench Specifications Tool Dimensions Plier For lock ring For ø25 axis ...

Page 536: ...SP001630 Swing Motor Page 22 Figure 9 Special tool for removing the brake piston ...

Page 537: ...charge all hydraulic fluid in the motor casing and the port oil passage Use a clean dust free work area Handle parts with care to prevent dirt and dust form adhering Do not over disassemble 2 Separating the motor and the reduction gear Secure the swing device in a vice and remove the socket head bolt 43 3 Secure the motor assembly in a vice and remove the socket head bolt 43 4 Separate the valve c...

Page 538: ...SP001630 Swing Motor Page 24 5 Remove the valve plate 18 6 Remove the bearing 5 and the pin 22 7 Remove brake springs 17 8 Remove the O ring 26 27 Figure 13 Figure 14 Figure 15 Figure 16 ...

Page 539: ...acing the motor horizontally remove the cylinder block 13 and other associated parts When taking out the cylinder block be careful not to pull out spring 12 Be careful not to damage the sliding parts of the cylinder block spherical bush and shoe 12 Remove the retainer plate 8 and the piston assembly 9 10 Figure 17 Figure 18 Figure 19 Reference Number Description 8 Retainer plate 9 Piston assembly ...

Page 540: ...SP001630 Swing Motor Page 26 13 Remove the spherical bush 11 14 Remove the cylinder spring 12 15 Remove the drive shaft 3 16 Remove the shoe plate 7 Figure 21 Figure 22 Figure 23 Figure 24 ...

Page 541: ...d parts Disassembling is finished check each component throughly Figure 25 Figure 26 CAUTION Do not disassemble the relief valve assembly because it is a functional component Figure 27 Figure 28 Reference Number Description 30 Spool 31 Spring 32 Plunger A assembly 33 Plunger A assembly 34 Plunger A assembly 35 Plunger A assembly 36 Plunger A assembly 37 Plunger A assembly 38 Plug ...

Page 542: ... please use a torque wrench etc and tighten the bolts with the torque shown 1 Place casing 1 on the work table with the valve casing side downward 2 Assemble the spool 30 and other associated parts 3 Assemble plunger 19 and spring 20 to casing 1 and tighten RO plug 21 with O ring Confirm the smooth movement of the plunger before installing the plug Figure 29 Figure 30 Reference Number Description ...

Page 543: ...e the relief valve 44 5 Assemble roller bearing 4 in the casing 1 with a using of tool 6 Apply grease to the back side of the shoe plate 7 and assembly it 7 Assemble the drive shaft 3 in the casing 1 Figure 32 Figure 33 Figure 34 Figure 35 ...

Page 544: ...semble the cylinder spring 12 10 Assemble the spherical bush 11 11 Set the piston assembly 9 10 on the retainer plate 8 and assembly it in the cylinder block 13 Figure 36 Figure 37 Figure 38 Figure 39 CAUTION Apply an ample amount of hydraulic fluid to the sliding part before assembly ...

Page 545: ...13 and other associated parts 13 Assemble the friction plate 14 2EA and separation plate 15 1EA 14 Assemble the brake piston 16 15 Assemble the brake spring 17 Confirm the springs are fitted to the brake piston completely Figure 40 Figure 41 Figure 42 Figure 43 ...

Page 546: ... careful to note the direction of the valve plate Mount the valve plate with its round part toward the opposite side of the flange Coat lightly with grease 19 Assembly the valve casing 2 Figure 44 Figure 45 Figure 46 Figure 47 CAUTION When separating the valve casing 2 be careful not to drop the valve plate 18 or let the brake springs pop out ...

Page 547: ...SP001630 Page 33 Swing Motor 20 Mount valve casing 2 to casing 1 and tighten hex socket bolts 43 to specification The assembly is completed Figure 48 ...

Page 548: ...arts names indicate the parts number shown by the drawing in the instruction and maintenance manual 1 Wind the wire rope at reduction gear outside lift up the reduction gear and clean the reduction gear with cleaning oil After cleaning dry with compressed air 2 Remove the sun gear No 1 R18 3 Remove the carrier No 1 sub assembly R9 4 Remove the sun gear No 2 R17 Figure 49 Figure 50 Figure 51 ...

Page 549: ...se loctite was used during assembly To facilitate the removal of the screw warm the screw with a drier 8 Remove the following parts Figure 52 Figure 53 Reference Number Description 42 Snap ring R12 Inner ring No 1 R14 Needle bearing R16 Planet gear No 1 R19 Thrust washer No 1 R21 Thrust washer No 2 Figure 54 Figure 55 Reference Number Description R10 Thrust washer No 3 R11 Inner ring No 2 R13 Need...

Page 550: ...ng is finished check each component throughly Figure 56 Figure 57 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 58 Figure 59 CAUTION The removed oil seal must not be used again When removing it exercise care to prevent damage to the outer races of the taper roller bearings ...

Page 551: ... hydraulic oil D Replace oil seal 1 Place the gear casing R1 on the work table 2 Press to insert oil seal R5 by using pressing jig after spreading grease oil around the outside ring of the oil seal Coat grease oil slightly on the lip surface to prevent any scratch when installing Be sure to check by eye that the oil seal is seated completely after being inserted 3 Install the bearing cover R6 and ...

Page 552: ...ll the half collar R7 with a using of tool 7 Install the following parts Figure 63 CAUTION Prior to assembling the pinion shaft etc Apply grease slightly on the lip surface to prevent any scratch when installing Figure 64 Figure 65 Figure 66 Reference Number Description R10 Thrust washer No 3 R11 Inner ring No 2 R13 Needle bearing R15 Planet gear No 2 ...

Page 553: ...ion of sun gear when assembling 11 Install the following parts Figure 67 Reference Number Description R20 Thrust plate R22 Screw CAUTION Apply loctite to the screw prior to tightening it Figure 68 Figure 69 Figure 70 Reference Number Description 42 Snap ring R12 Inner ring No 1 R14 Needle bearing R16 Planet gear No 1 R19 Thrust washer No 1 R21 Thrust washer No 2 ...

Page 554: ...atching holes when assembling 13 Install the sun gear No 1 R18 Be sure to check the direction of sun gear when assembling 14 Install the O ring 26 15 Place the motor assembly on the reduction gear assembly and loosely tighten the socket bolt 43 then tighten it the specified torque Figure 71 Figure 72 Figure 73 Figure 74 ...

Page 555: ... mm Recommended Value for Replacement mm Remedy Clearance between piston and cylinder bore 0 034 0 044 Replace piston or cylinder block Gap between piston and caulked part of shoe δ 0 1 0 3 Replace piston or shoe Thickness of shoe t 3 8 3 6 Replace piston or shoe Assembled height of retainer plate H h 13 2 12 7 Replace spherical bush and retainer as a pair Thickness of friction plate 2 8 2 4 Repla...

Page 556: ... Displacement 31 876 4 teeth 31 576 Replace Z 20 No 1 Carrier internal gear Overpin 42 171 ø6 42 771 Replace Z 17 No 2 Sun gear Displacement 23 269 3 teeth 22 969 Replace Z 17 No 2 Planet gear Displacement 31 876 4 teeth 31 576 Replace Z 20 No 2 Carrier internal spline Overpin 55 255 ø5 55 855 Replace Z 24 Pinion shaft external spline Overpin 69 343 ø4 5 68 743 Replace Z 24 Pinion shaft gear Displ...

Page 557: ...g surface to a standard roughness level or finer If the sliding surface of the cylinder block valve plate retainer plate or spherical bush is roughness replace parts as sub assemblies Item Surface Roughness Roughness Requiring Correction Shoe 0 8 Z Ra 0 2 LAPPING 3 Z Ra 0 8 Shoe Plate 0 4 Z Ra 0 1 LAPPING 3 Z Ra 0 8 Cylinder Block 1 6 Z Ra 0 4 LAPPING 12 5 Z Ra 3 2 Valve Plate 0 8 Z Ra 0 2 LAPPING...

Page 558: ...SP001630 Swing Motor Page 44 ...

Page 559: ...SP001686 Page 1 Travel Motor SP001686 TRAVEL MOTOR SP001686 Travel Motor Edition 1 ...

Page 560: ...SP001686 Travel Motor Page 2 MEMO ...

Page 561: ...nterbalance Operates 11 When Brake Functions 12 Operating Principle of Parking Brake 13 2 Speed Limiting Function 14 Parts List 16 Hydraulic Motor 16 Reduction Gear 18 Special Tools and Materials 20 Standard Tools 20 Equipment and Materials 21 Measuring Devices 21 Manufacturing Tools 22 Tightening Torque 26 Weight Table 26 Travel Motor Troubleshooting 27 Travel Motor 27 Counterbalance Valve 27 Rel...

Page 562: ...9 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 72 ...

Page 563: ...SP001686 Travel Motor Page 5 MEMO ...

Page 564: ...ow 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 565: ...the energy of the pressurized oil discharged from the pump into mechanical energy and also transfers high speed torque power to the decelerator Features Small size and light weight due to integration of motor and decelerator into one unit The internal counter adjuster permits adjustment of the quantity of oil supplied and prevents reverse rotation The brake circuit includes both counter adjusting ...

Page 566: ...al Diagram of the Travelling System Figure 1 Reference Number Description 1 Axial Piston Motor 2 Decelerator 3 Counter Adjusting Valve 4 Parking Brake 5 Crossover Relief Valve 6 2 speed Travel Changeover Device Reference Number Description ...

Page 567: ...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 Figure 2 Reference Number Description 1 Shaft 2 Valve Plate 3 Piston Assembly 4 Swash Plate 5 Retainer Plate Reference Number Description ...

Page 568: ...flow past the check valve causing the discharge pressure of the pump to rise The hydraulic oil whose pressure has increased passing through P1 port will act on the end of the plunger and push the plunger to the right When the pressure at P1 port overcomes the set spring pressure the plunger will move to the right and the fluid returning from M2 port will flow through the notch at the plunger edge ...

Page 569: ...d delaying the action of the hydraulic motor When revolution of the hydraulic motor is delayed the pressure of port P1 will increase thus allowing hydraulic oil flowing through the control valve to drive the hydraulic motor At this time the plunger will move to the right side due the increase in pressure of port P1 and the notch on the outer pillar of the plunger will open wide thus resulting in t...

Page 570: ...to spring force thus shutting notch on the outer pillar of the plunger Nevertheless because the hydraulic motor tends to continue to revolve due to inertia force it will continue pumping operation thus causing pressure of port M2 to increase This increased pressure will operate the relief valve thus discharging hydraulic oil to port M1 This will result in absorbing shock pressure arising from iner...

Page 571: ...n 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 When stopping the release port of the parking brake will be closed and pressurized oil inside the brake chamber will drain into the casing causing spring force to have the brake operate...

Page 572: ...n 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 swash plate to influence those pistons At that time l1a sum of forces F Fs1 that centering on the rotational axis influences the tilting plate will exceed l0 a sum of forces Fpi Fs2 that influences those ...

Page 573: ...re P2 low pressure transfer to respective pistons controlling tilting plates Consequently forces Fp1 Ap p1 Fp2 Ap p2 which press tilting plates will be created on the pistons controlling the tilting plates At this time l1 the sum of forces F Fs1 that centering on the rotational axis influences the tilting plate will be less than l0 the sum of forces Fpi Fs2 that influences those pistons thus makin...

Page 574: ...SP001686 Travel Motor Page 16 PARTS LIST Hydraulic Motor Figure 9 ...

Page 575: ...g 149 Ball Bearing 150 Ball Bearing 151 Roller 161 Piston 162 Shoe 167 Pivot 169 Mating Plate 177 Parallel Pin 190 Spring Valve 201 Rear Flange 218 Valve Seat 219 Valve 220 Spring 221 Plug 222 Ring 223 Spool 224 Plug 225 Stopper 226 Plug 227 Valve 228 Spring 230 Spring 233 O ring 236 O ring 237 O ring 241 Parallel Pin 243 Hex Socket Head Bolt 252 Hex Socket Head Plug 254 Hex Socket Head Plug 263 P...

Page 576: ...SP001686 Travel Motor Page 18 Reduction Gear Figure 10 ...

Page 577: ...Cover 9 Crank Shaft 12 Spacer 17 Pin 18 Ring 19 Reamer Bolt 20 Retaining Ring 21 Ball Bearing 22 Tapered Roller Bearing 23 Needle Roller Bearing 24 Retaining Ring for Shaft 25 Retaining Ring for Shaft 27 O ring 29 O ring 30 O ring 31 Floating Seal 33 Plug 35 Hex Head Bolt 36 O ring 42 Parallel Pin Reference Number Description ...

Page 578: ...ominal 8 mm 33 34 226 Socket Insert Angle 12 7 mm Nominal 24 mm 19 35 Nominal 30 mm 224 Extension bar Insert Angle 12 7 mm 19 35 Spanner Nominal 30 mm 224 Hand Hammer Nominal 12 mm 1 21 Plastic Hammer ABT 300 mm 8 102 Retaining Ring Pliers For shafts 24 25 For Holes 20 145 Center Punch ø9 5 x 100 1 Pin Punch ø3 x 150 21 Washing Brush For Washing Wire Washing Brush For Washing Paint Maker Paint Mak...

Page 579: ...l Diameter 10 mm 0 394 in 1 Drill Diameter 2 mm 0 079 in 1 Crane GM Motor 1 2 Lathe 3 Grinder Compressed Air Supply Pressure 0 29 0 49 MPa 3 5 kg cm2 42 71 psi For Drying Washed Parts Name Description Applicable Parts Thickness Gauge Measurement 0 04 0 3 mm 0 0016 0 0118 in For Adjusting Thickness of Retaining Ring 20 External Micrometer Measurement Range 0 0 25 mm 0 0 0098 in Min Graduation 0 01 ...

Page 580: ...ssembling the travel motor Fixture For connecting spindle 2 and hub 1 Holder I For inserting spring 114 washer 110 and retaining ring 145 into cylinder block 104 For removing spring 114 from cylinder block 104 Holder II For removing ball bearing 149 from or inserting it onto shaft 102 Figure 11 Figure 12 Figure 13 Figure 14 ...

Page 581: ... oil seal hole the spindle 2 Holder IV For installing the RV gear assembly on spindle 2 Steel Rod For removing ring 18 from hub 1 For removing ring 265 from rear flange 201 Bearing Preload Adjuster For adjusting the preload of ball bearing 21 Figure 15 Figure 16 Figure 17 Figure 18 ...

Page 582: ...indle 2 For removing ball bearing 21 and pin 17 from hub 1 PF Eye Bolt For lifting cover 8 Eye Bolt For lifting the GM motor hub 1 ad spindle 2 F S Installation Tool I For installing floating seal 31 to hub 1 Figure 19 Figure 20 Figure 21 A Hub M14 Spindle M14 GM Motor M14 Figure 22 ...

Page 583: ...lling floating seal 31 to hub 1 and spindle 2 F S Installation Tool III For installing floating seal 31 to spindle 2 Cover Removable Tool For removing cover 8 from hub 1 Slice For removing timing plate 109 from rear flange 201 Figure 23 Figure 24 Figure 25 Figure 26 ...

Page 584: ... m 29 4 4 9 Nm 22 4 ft lb 224 Plug M25 P1 5 30 mm 2 20 1 5 kg m 196 14 7 Nm 145 11 ft lb 226 Plug M20 P1 5 8 mm 3 8 0 1 0 kg m 78 5 9 8 Nm 58 7 ft lb 243 Hexagon Socket Bolt M8 P1 25 6 mm 6 3 0 0 5 kg m 29 4 4 9 Nm 22 4 ft lb 252 Hexagon Socket Plug PT 1 8 5 mm 3 1 25 0 25 kg m 12 3 2 45 Nm 9 2 ft lb 254 Hexagon Socket Plug NPTF 1 16 4 mm 4 1 0 0 2 kg m 9 81 1 96 Nm 7 1 ft lb 280 Plug M6 P1 0 1 1 ...

Page 585: ...nd O rings Replace broken oil seal and O rings Coat O rings with small quantity of grease when replacing Applicable Parts Component Weight Slow or No Rotation Plungers will not change over Hydraulic oil will not circulate Foreign objects between the plunger and the base plate Clogged orifice Check if hydraulic line is damaged Replace or repair damaged parts and install after cleaning Assemble afte...

Page 586: ...fice Large Shock When Stopping Shock absorbing function not operating Foreign objects in pistons Remove foreign objects Relief valve set pressure is too high Readjust pressure Applicable Parts Component Weight Wandering Spools will not change over Foreign objects in spools and valve body Damaged springs Broken spring Remove foreign objects Reinstall springs Replace springs Oil leak in 2 speed cont...

Page 587: ...re of any abnormalities which might occurr and work according to the disassembly procedure 2 Each part is manufactured to extreme precision Handle with care and be sure not to hit the parts together or drop them 3 When working do not attempt to beat forcefully or wrench tightly fitting parts Doing so could produce burrs or damage the parts so they can t be mounted or may reduce their performance Y...

Page 588: ...o signs of damage You should have a new ready when disassembling 8 The photographs and drawings contained in the manual are of representative models Disassembly procedure is however not affected even if the product you are using differs in part Disassembly Procedure Washing GM motor 1 Fasten the eyebolts to spindle 2 NOTE Fasten the 2 eyebolts in the screw holes for mounting the spindle so they ar...

Page 589: ... flange only proceed to below item 7 1 Invert the GM motor 2 Loosen and remove plugs 33 hex socket plug 34 NOTE When extracting lubricating oil place a container below the workbench 3 Dispose of drained fluids according to local regulations 4 Slowly invert the GM motor and extract the lubricating oil 5 Remove 0 ring 36 from plug 33 and hex socket plugs 2 plugs NOTE Do not reuse O ring 36 which has...

Page 590: ... the hub B Using an electric drill make a 2 mm 0 079 in diameter hole at a punch mark NOTE Be sure to center the drill on the punch mark and keep drilling until the ring starts rising After drilling clear through the wall of the hub be sure to wipe off the chips completely C Insert the steel rod into the drilled hole and push the ring out Figure 33 CAUTION Be careful when removing the ring You cou...

Page 591: ...to lift the cover off shake the cover loose by tapping on it with a plastic hammer so that the cover will slide out without cocking NOTE Do not reuse O ring 29 which has been removed Input Gear Removal 1 Remove retaining ring 24 from shaft 102 2 Draw out input gear 6 from shaft 102 Figure 37 Figure 38 Figure 39 CAUTION Be careful when removing the retaining ring You could become injured if tip of ...

Page 592: ...lange 201 is on top 2 Loosen plugs 224 2 plugs NOTE Temporarily loosen the plugs to make work easier later 3 Loosen plugs 226 2 plugs NOTE Temporarily loosen the plugs to make work easier later Figure 41 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 Figure 42 Figure 43 Figure 4...

Page 593: ...old the rear flange with both hand and gently lift it straight up be careful not to cock it while lifting Remember timing plate 109 will come out with the rear flange 6 Pull out parallel pins 42 2 pins from spindle 2 7 Remove O rings 30 27 from spindle 2 NOTE The removed O rings should be replaced with new ones even if they are free from damage Figure 45 Figure 46 Figure 47 ...

Page 594: ...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 Never try to pry timing plate off with a sharp or pointed tool or the precision finished mating faces will suffer costly damaged 3 Pull out ball bearing 150 from rear flange 201 4 Pull out two parallel pins 241 from rear flange 201 Figure 48 Figure ...

Page 595: ... two holes take out spring 228 and stopper 225 3 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 4 Remove two plugs 226 from rear flange 201 5 Remove two springs 230 and two valves 227 from rear flange 201 Figure 51 Figure 52 Figure 53 Figure 54 ...

Page 596: ...ng it from the ring groove in rear flange 201 Ring 265 can now be removed from rear flange 201 NOTE Do not reuse O ring which has been removed 2 Insert the rear flange so that ring hole from which the ring was removed comes down and lift rear flange 201 to remove stopper 264 spring 266 and valve 263 NOTE When removing the ring from its hole it may be scratched Correct any scratched hole surface Do...

Page 597: ...ngaging it from ring groove in the rear flange Ring can not be remove from the rear flange NOTE When removing the ring from its hole it may be scratched Correct any scratched hole surface Do not reuse the disassembled ring Removed O rings should be replaced with new ones even if they are free from damage 2 Block port for valve seat 218 and apply compressed air into access hole in the rear flange 3...

Page 598: ...ust below the motor to catch oil 2 Take out friction plate 215 and mating plates 216 269 3 Hold cylinder block 104 by hand turn alternately 2 3 times and cut away shoe 106 bonded to swash plate 103 NOTE If the cylinder block has been removed as is shoe remains bonded to the swash plate and the parts piston shoe and etc mounted on the cylinder block and fall into the spindle 4 Draw out cylinder blo...

Page 599: ...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 6 Remove the piston assembly from retainer plate 107 7 Remove thrust ball 108 from cylinder block 104 8 Draw out three needle rollers 151 from cylinder block 104 Figure 64 Figure 65 Figure 66 Figure 67 ...

Page 600: ...surfaces of the cylinder block from being damaged 2 Place holder I on washer 110 and while clamping holder with the press remove retaining ring 145 with a retaining ring pliers 3 Remove spring 114 and washer 110 from cylinder block 104 Removal of Swash Plate 1 Take out swash plate 103 from the shaft 2 Remove shaft 102 and ball bearing 149 on it as well from spindle 2 3 Remove pivots 167 and pins 1...

Page 601: ... Flange 1 Turn the workbench so the spindle is on top 2 Fasten the fixture jig to the hub spindle NOTE This clamping is necessary because the hub is sandwiched between the spindle and hold flange Cramp the spindle and hub securely before removing the hold flange so that the spindle will not fall from the workbench 3 Turn the workbench upside down 4 Remove retaining rings 20 2 rings from hold flang...

Page 602: ...cification for these bolts is 25 7 kgf m 252Nm 186 ft lb but much greater torque of up to 25 7 kgf m 252Nm 186 ft lb may be needed to loosen them because of the loctite 8 Loosen hex head bolt 35 NOTE Locktite 638 is used on screw threads of the hex head bolts For these reason they might behave as if they were seized in place When loosening them turn the torque wrench back and forth to break the lo...

Page 603: ...if one of them must be replaced replace both as a set at the same time A set of the spindle and hold flange is called the spindle assembly Fixture Removal 1 Invent the GM motor 2 Remove the fixture 2 fixtures Removing Spindle 1 Fasten eyebolts 2 bolts in the mounting holes of spindle 2 so they are symmetrically positioned 2 Hook on the eyebolt gently and slowly hoist with a crane and remove spindl...

Page 604: ...haft 9 tapered roller bearing 22 needle roller bearing with retainer 23 spacer 12 and pin 17 can be taken out together 3 Remove ball bearing 21 RV gear assembly and pin 17 which have fallen NOTE Tapered roller bearing 22 needle roller bearing 23 and spacer 12 are not removed from crank shaft 9 except when replacing Ball Bearing Removal NOTE When removing ball bearing 21 falls from hub 1 Place a ru...

Page 605: ...t in parts 2 Wash the built in parts in a washing bath NOTE Carefully wash to remove any darts from external surfaces Wash all parts carefully with kerosene 3 Full a primary washing vessel with kerosene Put the built in parts in it and wash them NOTE To prevent the built in parts from being marred by dirt during washing immerse the parts in kerosene long enough for any dirt or oil to become loose ...

Page 606: ... remove dripping kerosene NOTE Dry hub 1 spindle 2 and hold flange 3 by spraying with compressed air until they are dry and clean Let other parts dry naturally until they are dry and clean After drying coat every part with oil Take notice that all pins and ball roller for the bearings are carefully separated and surfaces protected from any damage to prevent flaws to the pins and ball rollers Figur...

Page 607: ...ex Socket Bolt Serious damage in appearance Abnormal wear such as scuffing 4 9 22 23 12 RV gear assembly RV gear Crankshaft Tapered roller bearing Needle roller bearing Spacer RV gear teeth surface are worn unequally Movement of various parts not smooth when crankshaft 9 is tuned 20 Retaining ring Circumferential end face has abnormal wear 21 Ball bearing Has indentation Exhibits flaking phenomeno...

Page 608: ... the piston 105 and shoe 106 Shoe is abnormally worn Shoe is unequally worn Clearance 0 050 mm 0 0020 in Clearance 0 150 mm 0 0059 in 107 Retainer plate Circumference and face is unequally worn 108 Thrust ball Ball surface has burning phenomenon and equal wear 227 Valve Flaw in sheet surface 149 150 Ball bearing Has indentation Exhibits flaking phenomenon Worn unequally 263 Valve Flaw on circumfer...

Page 609: ...eamer bolt 19 hex socket bolt 35 and screw holes of reamer bolt 19 hex socket bolt 35 of spindle 2 when assembling Degrease in order to remove grease 6 Be careful not to damage O rings oil seals and floating seals when mounting Apply a small amount of grease to make them slippery 7 Be sure to coat the moving and sliding parts of the hydraulic motor section and valve section with clean hydraulic fl...

Page 610: ...ove be sure to assemble using parts which have been adjusted If you assemble with parts that have not been adjusted it will cause the travel motor to operate poorly or break down prematurely Hub Section Assembly 1 Fasten 2 eyebolts in the screw holes of hub 1 so they are symmetrically positioned 2 Hook the wire in the eyebolts hoist the hub 1 with a crane and set hub 1 on the workbench NOTE While ...

Page 611: ...nstallation tool I Remove the installation tools and check the inclination of the floating seal surface to make sure it is within 1 mm 0 0394 in Spindle Assembly 1 Apply oil thinly on the outside circumference of the O ring of floating seal 31 and mount the floating seal in the floating seal groove of the spindle 2 NOTE To mount the floating seal place the F S installation tool III floating seal a...

Page 612: ... them slowly and equally 6 Turn the workbench upside down Mount RV Gear Assembly 1 Install RV gear 4 In the hub 1 2 Install the crank shaft 9 2 shafts in the hub 1 NOTE Match the inner race of the tapered roller bearing 22 of the crank shaft 9 with the outer race hole of the tapered roller bearing 22 fit in the spindle 2 3 Install RV gear 4 in the hub 1 Figure 97 Figure 98 Figure 99 Figure 100 ...

Page 613: ...g 1 Check if the hub 1 spindle kit ball bearing 21 2 bearings parts have been replaced with new ones NOTE If there are no renewal parts proceed to the next step If there is even 1 renewal part proceed to the next step after carrying out Preload Adjustment of Ball Bearing on page 1 69 2 Install the hold flange 3 on the spindle 2 Make sure the match mark is in the same position as when it was disass...

Page 614: ...wly and evenly to position the hold flange 3 Apply bonding agent to screw section of hex socket bolts 35 2 bolts NOTE If the hex socket 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 4 Fasten the hex socket bolts 35 2 bolts with specified torque NOTE Tightening torque 25 7 4 0 ...

Page 615: ...ing ring 20 that is identical with or equivalent to the replaced retaining ring must be selected from 15 available types 2 Install retaining rings 20 into the retaining ring grooves in the hold flange 30 NOTE Install the two retaining rings in the same position as before disassembly as indicated by the match marks on the hold flange if new retaining ring is used select this retaining ring having a...

Page 616: ...haft 9 by matching the counter marks punch holes Figure 111 as shown in the Figure 111 2 Install retaining rings 25 into the retaining ring groves in the crank shafts 9 Mounting Oil Seal 1 Turn the workbench upside down 2 Apply lithium grease to the lip section of the oil seal and press fit the oil seal 132 into spindle 2 with the holder III and hammer Figure 109 Figure 110 Figure 111 Figure 112 ...

Page 617: ...e piston assembly apply hydraulic oil to the piston assembly 4 Insert the parallel pins 177 2 pins into the pin holes of the spindle 2 5 Apply lithium grease to the hemispherical surface of the pivots 167 and fit into the parallel pins 142 of the spindle 2 6 Turn the work bench 90 degrees 7 Fit the motor shaft 102 slowly into the spindle 2 NOTE Take care not to scratch or cut the lip portion of th...

Page 618: ...it the retaining ring 145 in the retaining ring groove of the cylinder block 104 with a retaining ring pliers Assembly of Hydraulic Motor Parts 1 Place the needle rollers 151 3 rollers cylinder block 104 and place the thrust ball 108 on top 2 Install the nine piston assembly 105 106 into retainer plate 107 NOTE After assembling dip the whole thing in hydraulic fluid 3 Fit retainer plate 107 and 9 ...

Page 619: ...nner circumference groove of the spindle 2 and the section in cylinder block 204 NOTE Install the friction plate after applying the hydraulic fluid 3 Fit O rings 235 239 to piston 212 At this time apply a thin coat of grease to the O rings 4 Install piston 212 in spindle 2 NOTE If the piston doesn t fit into the spindle because or the resistance of the O rings tap the edge of the piston lightly an...

Page 620: ...23 into the rear flange 201 NOTE Apply hydraulic liquid to the spool and insert the spool into the rear flange Insert the spool straight into the bore taking care not to damage the sliding surfaces of the spool and the bore so that there will be no internal leakage of oil along the spool Bear in mind that such 5 Fit the O ring 236 to the plug 224 2 plugs NOTE Apply grease to the O ring 236 6 Insta...

Page 621: ...he stopper 264 on it 4 Slightly bend a new ring 265 and insert it into the rear flange 201 from the top of stopper 264 Then fit the new ring 265 into the groove of the rear flange 201 NOTE The ring used must be fitted snugly into the ring groove of the rear flange Improper insertion of the ring into the ring groove may cause unstable of the valve thus disassembling high low speed selection The rin...

Page 622: ...ly grease to the mating face with the rear flange 201 of the timing plate 109 NOTE Fitting of timing plate 109 is carried out until the timing plate adheres to the rear flange 201 Adhesion prevents the timing plate from falling from the rear flange when mounting the rear flange on spindle 2 8 Fit the timing plate 109 on the rear flange 201 using the parallel pin 241 as a guide Figure 131 Figure 13...

Page 623: ...l motor is running This may be mistaken as an oil leak so do not apply grease 2 Insert the parallel pins 142 2 pins into the spindle 2 3 Put 0 3 liters of hydraulic fluid in the spindle 2 4 Install the rear flange 201 onto the spindle 2 so that two parallel pins 142 on the spindle enter the pinholes in the rear flange 201 5 Tighten hex socket bolts 243 6 bolts equally and evenly with specified tor...

Page 624: ...6 with specified torque NOTE Tightening torque 8 1 kgf m 78 5 9 8 Nm 8 0 kg m 58 7 ft lb Input Gear Assembly 1 Turn the workbench upside down 2 Install the input gear 6 to the shaft 102 NOTE The teeth of the input gear should mesh smoothly with the two spur gears 3 Fit the retaining ring 24 to the shaft 102 Figure 138 Figure 139 Figure 140 Figure 141 ...

Page 625: ...he cover 8 on the hub 1 make sure the match mark is in the same position as it was disassembled After positioning the cover force it into the hub by lightly hammering with a plastic hammer on and around its rim 4 Install the ring 18 into the hub 1 5 Fit the O ring 36 to the plugs 33 Tighten plugs 33 with the specified torque to the cover 8 NOTE Tightening torque 6 1 kgf m 58 8 9 8 Nm 43 7 ft lb Fi...

Page 626: ...2 Remove the hex socket bolts 2 bolts securing the GM motor to the workbench 3 Fasten the eyebolts 2 bolts to the spindle 2 NOTE Be sure that the two eyebolts are opposite to each other 4 Hook the hook and wire on the eyebolts and remove the GM motor from the work bench with a crane Figure 146 Figure 147 ...

Page 627: ...Preload check and preload adjustment instructions are as follows 1 Ball bearing 21 preload adjustment procedure A Mount the main bearing preload adjustment jig on the spindle 2 tighten the special nut and apply preload to the ball bearing 21 Special nut tightening torque 5 kgf m 49 Nm 36 ft lb NOTE The hold flange and spindle have been machined as a pair and are therefore configured as an assembly...

Page 628: ...y or break down prematurely If not replacing the parts listed above retaining ring adjustment is unnecessary and main assembly is carried out from Install Retaining Rings on page 1 57 as is Shaft direction clearance adjustment method of the tapered roller bearing is as fellows 1 Apply holder IV to the outer ring of the tapered roller bearing 22 on the crank shaft 9 and lightly hammer the holder NO...

Page 629: ...auge 5 Determine whether the thickness of the retaining ring is suitable Max Thickness of thickness gauge Thickness of currently mounted ring Min Thickness of thickness gauge Thickness of currently mounted ring 0 05 mm 0 002 in 6 After deciding thickness of the retaining ring select another retaining ring from 12 available types fit it into the hold flange 7 After fitting the retaining ring of the...

Page 630: ...n be measured NOTE When mounting the GM motor do not strike with a hammer etc but rather mount gently using the bolt holes Break in operation of the GM motor Speed ranges GM motor rpm Pressure Rotation direction Running time Low speed 10 rpm No load Left Right Min 1 minute each High speed 20 rpm GM motor performance confirmation test Good Attach the track shoe Not Good Disassemble and adjust again...

Page 631: ...m T 1 95 mm 0 0748 in T 0 0768 in E 1 95 mm T 2 00 mm 0 0768 in T 0 0787 in F 2 00 mm T 2 05 mm 0 0787 in T 0 0807 in G 2 05 mm T 2 10 mm 0 0807 in T 0 0827 in H 2 10 mm T 2 15 mm 0 0827 in T 0 0846 in I 2 15 mm T 2 20 mm 0 0846 in T 0 0866 in J 2 20 mm T 2 25 mm 0 0866 in T 0 0886 in K 2 25 mm T 2 30 mm 0 0886 in T 0 0906 in L 2 30 mm T 2 35 mm 0 0906 in T 0 0925 in M 2 35 mm T 2 40 mm 0 0925 in ...

Page 632: ...SP001686 Travel Motor Page 74 ...

Page 633: ...SP001639 Page 1 Main Control Valve SP001639 MAIN CONTROL VALVESP001639 Main Control Valve Edition 1 ...

Page 634: ...SP001639 Main Control Valve Page 2 MEMO ...

Page 635: ...m2 Aux Section Figure 35 10 Disassembly of Straight Travel Section Figure 39 10 Take Off of Load Check Poppet Type 11 Disassembly of Valve Housing 12 Cleaning 13 Inspection 13 Assembly 14 Assembly of Valve Housing 14 Assembly of Arm2 Bucket Right Run Left Run Arm1 Dozer Swing Boom2 Aux Boom Swing 15 Assembly of Boom1 Section Figure 30 15 Assembly of Inlet Section Figure 32 15 Assembly of Boom2 Aux...

Page 636: ...SP001639 Main Control Valve Page 4 Operation 24 SPEC of Control Valve 24 Failure and Troubleshooting 25 Overall Control Valve 25 Relief Valve 26 Overall Pneumatic System 26 ...

Page 637: ...ollow 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 638: ...avel Section Figure 39 Function of Control Valve 1 Control for neutral Oil discharges from the return port through the center bypass passage within the main control valve 2 Operation of control valve Such control changes flow direction of oil in order to change operation stop or to change operation direction of both cylinder and motor Pump oil is supplied to each section from the enter bypass pass...

Page 639: ...p is returned to the tank through neutral passage Working oil of both A1 and B1 cylinder port is closed 2 Crowd operation Figure 12 If converting the spool by pressurizing the Pa1 port flow of the neutral passage is closed and working oil in the neutral passage pushes up the load check valve at both places and flow through A1 Working oil of the cylinder port B returns to the tank from the Arm1 sec...

Page 640: ...ral Figure 20 and Operation Figure 21 working oil is supplied to Boom1 through inside passage of the control valve Lift Up Mix Arm1 For Neutral Figure 22 Crowd Operation Figure 23 and Dump Operation Figure 24 some of working oil returned from the cylinder port B6 returns to the tank and the other oil pushes up poppet for recovery and supplies oil to A6 recovery circuit Straight Travel Figure 25 Fo...

Page 641: ... Combination No 15 16 17 of Figure 27 Disassembly of Arm2 Bucket Right Run Left Run Arm1 Dozer Swing Boom Swing Section Take off the cap of Combination No 3 of Figure 28 Figure 29 Figure 31 Figure 32 Figure 33 Figure 36 Figure 37 Figure 38 by loosening a 13 socket head bolt hexagonal hole subtense 5mm Remove 4 spring seat 6 spring 5 spring seat and 12 O ring Then take out the 2 spool from the 1 va...

Page 642: ...is manner also take out the opposite 3 cap Disassembly of Boom2 Aux Section Figure 35 Take out the cap of Combination No 3 of Figure 35 3 by loosening a 13 socket head bolt hexagonal subtense 5mm Remove 4 spring seat 6 spring 5 spring seat and 12 O ring Then take out the 2 spool from the 1 valve housing In this manner take out the opposite 16 cap by loosening a 13 socket head bolt hexagonal subten...

Page 643: ...g 2 9 spring 2 7 poppet 8 poppet Boom1 Figure 30 21 Plug assembly 2 10 Plug 2 9 spring 2 8 poppet 2 Right Run Figure 31 7 Plug Inlet Figure 32 7 Plug assembly Left Run Figure 33 7 Plug Arm1 Figure 34 10 Plug 9 spring 7 poppet 18 Plug 16 spring 15 poppet Boom2 Aux Figure 35 15 Plug assembly 2 10 Plug 9 spring 7 poppet Dozer Figure 36 10 Plug 9 spring 7 poppet Boom Swing Figure 37 10 Plug 9 spring 7...

Page 644: ...t disassembled by section so that position to squeeze and insert can be known for reassembly Arm2 Figure 28 No parts Bucket Figure 29 14 O ring Boom1 Figure 30 12 O ring Right Run Figure 31 12 poppet 13 spring 11 O ring Inlet Figure 32 6 O ring 2 Left Run Figure 33 12 poppet 13 spring 11 O ring Arm1 Figure 34 14 O ring 19 O ring 21 O ring Boom2 Aux Figure 35 14 O ring Dozer Figure 36 14 O ring Boo...

Page 645: ...oove surface of the valve housing is smooth and that there are scraps dented point and rust etc 2 If there is dented point or defect on the check sheet surface of the valve housing get away it by wrapping Be cautious so that wrapping agents not remain within the valve 3 All the interface and relief parts must lightly move There should no dirt on all the grooves or passages 4 When spring is damaged...

Page 646: ...ing Insert below poppet spring into the housing Mount O ring in the matching surface as below on each section Then orderly adhere Inlet housing and valve housing of each section to the tie rod of Figure 27 Combination No 1 And firmly tightening 2 nut hexagonal subtense 8mm to 1 tie rod Tightening torque 26 5 29 4 N m Right Run Figure 31 12 poppet 13 spring Left Run Figure 33 12 poppet 13 spring Ar...

Page 647: ...efore disassembly and then mount the 7 anti drift valve assembly equipped with the 13 O ring with a 20 socket head bolt hexagonal hole subtense 5mm Tightening torque 8 8 10 8 N m Assembly of Inlet Section Figure 32 Insert the 2 spool right left symmetry of Figure 32 into 1 valve housing and mount the 3 cap equipped with the 4 O ring with a 5 socket head bolt hexagonal hole subtense 5mm Also mount ...

Page 648: ...hole subtense 5mm Left Run Figure 33 7 Plug assembly Plug Tightening torque 30 4 32 4N m hexagonal hole subtense 6mm Arm1 Figure 34 10 Plug 9 spring 7 poppet Plug Tightening torque 30 4 32 4N m hexagonal subtense 14mm 18 Plug 16 spring 15 poppet Plug Tightening torque 28 4 30 4N m hexagonal hole subtense 6mm Boom2 Aux Figure 35 15 Plug assembly Plug Tightening torque 37 2 41 2N m hexagonal hole su...

Page 649: ...ion 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 CAUTION Recheck that there are possibly not assembled or not tightened parts disassembled after completing assembly If not firmly tightening oil may leak due to loose parts Tightening torque as instructed in this manual shows value of wet status ...

Page 650: ...eve E are firmly seated due to difference of the area 2 If pressure of the HP reaching to force of the pilot spring to be set the Pilot poppet F is open Oil flows around poppet and is delivered to the low pressure passage LP through a hole 3 The Pilot poppet F opens and so oil flows from HP to D room through the throttle hole of the main poppet C By this pressure difference generates between HP an...

Page 651: ...ure 4 screw part and insert a new O ring 2 Figure 4 After properly cleaning the relief mounting part of the valve housing mount the relief valve and then tighten cam 1 Figure 4 1 hexagon subtense 24 to tightening torque of 69 78N m If disassembling the adjuster kits properly clean around the screw part and adjust pressure according to Hint for Disassembly and Assembly of Overload Relief Valve on p...

Page 652: ...e Pilot poppet E is open Oil flows around poppet and is delivered to the low pressure passage LP through a hole H 3 If the poppet E opens oil flows through the throttle hole I of the piston c and so pressure difference generates at the rear of the passage HP and the piston c The poppet E is seated due to movement of the piston c 4 Oil flows from the passage HP to the rear side of the poppet D only...

Page 653: ... side to the cylinder port HP and prevents cavitation Hint for Disassembly and Assembly of Overload Relief Valve 1 Disassembly For the original product replace assembly When replacing loosen the cap 1 hexagonal subtense24 with a spanner etc and take off the O ring 2 Figure 10 If oil leaks from the adjuster part 3 Figure 10 loosen the adjuster part and replace the O ring 4 Figure 10 Figure 9 Figure...

Page 654: ...rt the Plug 2 until the piston will touch with the section of Plug 4 subsidiary In this case the tightening torque of Plug 2 should be less than 19 6 N m However when tightening and inserting the Plug 2 be cautious so that Plug 4 should not rotate together P 12 ss A Length more than 4 mm Tighten and pressurize the Plug 4 Slowly tighten Plug 4 while seeing the pressure gauge 28 4MPa rotation of plu...

Page 655: ...ck that it becomes specified pressure Overload Relief Valve 1 Read value of the pressure gauge in the end of the cylinder stroke by replacing the spool of the control valve as 1 2 Turn adjuster clockwise until required pressure will be obtained 28 4MPa rotation of adjuster rises 3 When reaching to the specified pressure press the adjuster so that it should not rotate and tighten the lock nut Tight...

Page 656: ...rload relief valve is over 3 0Mpa 5 After fully performing preheat operation warming up perform actual work Especially for starting to operate the machine when working oil temperature or valve temperature is low care should be taken of following points for preventing a stick of heat shock A Evenly increase temperature of each part by operation so that working oil circulates within each actuator wi...

Page 657: ...ot equal Warm up the whole circuit 10 Scraps clogged within valve Remove scraps flashing 11 Pilot pressure insufficient Check Pilot valve and Pilot relief pressure Failing to maintain load 1 Oil leak from cylinder Check the cylinder room part 2 Oil bypassed in the spool Check possible spool damage 3 Oil leak from overload relief valve Clean some of valve housing seat or relief valve seat 4 Oil lea...

Page 658: ...ied torque Oil leak 1 Damage of relief valve part Replace relief valve 2 Each part stuck by scraps 3 O ring worn Replace O ring on the adjuster or the mounting part Failure Possible Cause Troubleshooting Pneumatic system fails or not operate 1 Failure of pump Check pressure or replace pump 2 Failure of relief valve Replace relief valve 3 Failure of cylinder etc Repair or replace 4 Pump load pressu...

Page 659: ...SP001639 Page 27 Main Control Valve Figure 11 Arm2 Neutral Figure 12 Arm2 Crowd ...

Page 660: ...SP001639 Main Control Valve Page 28 Figure 13 Arm2 Crowd simultaneous Operation with BOOM Figure 14 Arm2 Dump ...

Page 661: ...SP001639 Page 29 Main Control Valve Figure 15 Boom1 Neutral Figure 16 Boom1 Lift Up ...

Page 662: ...SP001639 Main Control Valve Page 30 Figure 17 Boom1 Lower Down ...

Page 663: ...SP001639 Page 31 Main Control Valve Figure 18 Travel R Neutral Figure 19 Travel R Pb4 ...

Page 664: ...SP001639 Main Control Valve Page 32 Figure 20 Boom2 Neutral Figure 21 Boom2 Lift Up Joint ...

Page 665: ...SP001639 Page 33 Main Control Valve Figure 22 Arm1 Reproduction Circuit Figure 23 Arm1 reproduction Circuit Figure 24 Arm1 reproduciton Circuit dump ...

Page 666: ...SP001639 Main Control Valve Page 34 Figure 25 Straight Travel Neutral Figure 26 Straight Travel Operation ...

Page 667: ...ssembly 8 Spool Section Assembly 9 Spool Section Assembly 10 Spool Section Assembly 11 Spool Section Assembly 12 Spool Section Assembly 13 Spool Section Assembly 14 Spool Section Assembly 15 Spool Section Assembly 16 Relief Valve Assembly 17 Relief Valve Assembly 18 Relief Valve Assembly 19 Shutoff Valve Assembly 20 Shipping Plug 21 Shipping Plug 22 Shipping Plug 23 Shipping Plug Reference Number ...

Page 668: ...lve Page 36 Figure 28 Arm2 Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Poppet 8 Poppet 9 Spring 10 Plug 11 O ring 12 O ring 13 Socket Head Bolt Reference Number Description ...

Page 669: ... Valve Figure 29 BKT Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Poppet 8 Poppet 9 Spring 10 Plug 11 O ring 12 O ring 13 Socket Head Bolt 14 O ring Reference Number Description ...

Page 670: ...lve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Anti Drift Valve Assembly 8 Poppet 9 Spring 10 Plug 11 O ring 12 O ring 13 O ring 14 Socket Head Bolt 15 Poppet 16 Spring 17 Spacer 18 O ring 19 Backup Ring 20 Socket Head Bolt 21 Plug Assembly Reference Number Description ...

Page 671: ...ntrol Valve Figure 31 T R Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Plug 8 O ring 9 O ring 10 Socket Head Bolt 11 O ring 12 Poppet 13 Spring Reference Number Description ...

Page 672: ... Valve Page 40 Figure 32 Inlet Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Poppet 8 9 Spring 10 Plug 11 O ring 12 O ring 13 Socket Head Bolt Reference Number Description ...

Page 673: ...ntrol Valve Figure 33 T L Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Plug 8 O ring 9 O ring 10 Socket Head Bolt 11 O ring 12 Poppet 13 Spring Reference Number Description ...

Page 674: ... Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Poppet 8 9 Spring 10 Plug 11 O ring 12 O ring 13 Socket Head Bolt 14 O ring 15 Poppet 16 Spring 17 O ring 18 Plug 19 O ring 20 21 O ring 22 Plug Reference Number Description ...

Page 675: ...re 35 Boom2 Aux Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Poppet 8 9 Spring 10 Plug 11 O ring 12 O ring 13 Socket Head Bolt 14 O ring 15 Plug Assembly 16 Cap Reference Number Description ...

Page 676: ...e Page 44 Figure 36 Dozer Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Poppet 8 9 Spring 10 Plug 11 O ring 12 O ring 13 Socket Head Bolt 14 O ring Reference Number Description ...

Page 677: ... Valve Figure 37 Boom Swing Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Poppet 8 9 Spring 10 Plug 11 O ring 12 O ring 13 Socket Head Bolt 14 O ring Reference Number Description ...

Page 678: ...e Page 46 Figure 38 Swing Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 Poppet 8 9 Spring 10 Plug 11 O ring 12 O ring 13 Socket Head Bolt 14 O ring Reference Number Description ...

Page 679: ...9 Straight Travel Reference Number Description 1 Valve Housing 2 Spool 3 Cap 4 Spring Seat 5 Spring Seat 6 Spring 7 O ring 8 Cap 9 10 11 Plug 12 O ring 13 Socket Head Bolt 14 Filter A 15 O ring 16 Name Plate 17 Screw Reference Number Description ...

Page 680: ...SP001639 Main Control Valve Page 48 ...

Page 681: ...SP001488 Page 1 Main Pump SP001488 MAIN PUMP SP001488 Main Pump Edition 1 ...

Page 682: ...SP001488 Main Pump Page 2 MEMO ...

Page 683: ...Procedures for Test Operation 16 Maintenance and Protection 17 Checking Filters 18 Filter Replacement 18 Replacement of Hydraulic Oil 19 Hydraulic Fluid Leakage Check 19 Diagnosis of Troubles and Actions to be Taken 20 Diagnosis of Troubles with the Pump 20 Solenoid Valve and Relief Valve 21 Disassembling and Reassembling hydraulic pump 22 Necessary Tools and Jigs 22 Reminders for Disassembly and ...

Page 684: ...SP001488 Main Pump Page 4 MEMO ...

Page 685: ...ty 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX55 50001 and Up DX60R 50001 and Up ...

Page 686: ...ucture 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 That is as the output is controlled by a constant value the relation between discharge pressure and flow rate Q remains constant P1 P2 x Q Pump No 3 and the pilot pump are connected on the same axle using a coupling Figure 1 ...

Page 687: ...ischarge Port G 3 4 JIS B2351 O TYPE A3 Discharge Port G 1 2 JIS B2351 O TYPE A1G A2G Gauge Port G 1 4 JIS B2351 O TYPE PA Pilot Port G 1 4 JIS B2351 O TYPE PB1 PB2 Pilot Port G 1 4 JIS B2351 O TYPE PPG Gauge Port G 1 4 JIS B2351 O TYPE R Air Discharge Port M10 x 1 With Bleeder Valve R1 R2 Drain Port G 1 2 JIS B2351 O TYPE ...

Page 688: ...s divided into two points by the control plate on the cover where it is discharged into two discharge ports Discharge pressure is determined by the control valve and the tilting plate by restoration strength of the spring The quantity of discharged flow may vary because piston strokes are changed according to the tilt angle At the same time a method is adopted to control a constant output of the t...

Page 689: ...SP001488 Page 9 Main Pump Figure 3 NO Name 1 Driving Axle 2 Tilting Plate 3 Rotary Group 4 Cover 5 Control Spring 6 Control Piston 7 Gear Pump 8 Housing 9 Solenoid Valve 10 Relief Valve NO Name ...

Page 690: ...is 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 Number Description 1 Relief Valve 2 Body 3 Solenoid Valve A 4 Solenoid Valve B Reference Number Description ...

Page 691: ...tilting point suction process While piston strokes are going on from upper tilting point toward lower tilting point piston moves towards direction in which quantity of discharged oil decreases The actuator oil is discharged into discharge port discharge process The quantity of discharged oil changes according to change in tilt angle of tilting plate tilting plate Actuator oil that came into ports ...

Page 692: ...ied to piston and spring A exceeds its set load and keeps its tilting face at point where hydraulic pressure is in equilibrium with strength of spring Refer to A in middle part of Figure 6 Tilt angle begins to decrease when hydraulic pressure is applied to piston and then spring B that so far has not worked begins to operate The two springs become to revive their spring tension when hydraulic pres...

Page 693: ...SP001488 Page 13 Main Pump Figure 6 ...

Page 694: ...uts B Tighten or release adjusting nuts for adjustment of the power changing curve Figure 7 Reference Number Description 1 Spring Seat 2 Cover 3 Adjusting Nut 4 Hex Nut 5 Tighten 6 Release 7 Total Pressure 8 Tighten 9 Release 10 Quantity of Oil Reference Number Description ...

Page 695: ... diesel engine Install an intake pipe be careful not to allow air to flow into pump 4 Use a high pressure flexible hose for discharge ports P1 and P2 5 Fully charge pump with hydraulic oil following its installation DRIVING 1 Use a flexible coupling when you connect it to the motor 2 Insert couplings near input axle Do not give strong impact to couplings while inserting 3 While viewing axle from e...

Page 696: ... 9 Check whether or not filter is correctly installed in same direction as that of the oil road 10 Check whether or not pump case is filled with hydraulic oil 11 Check whether or not control valve is adjusted to location of bypass 12 Operate the motor Drive it at a warm temperature at a low speed 13 Check whether or not system remains on no load condition when actuator gallery operates it correctl...

Page 697: ...d to case where the actuator oil tank especially actuator oil is replaced Maintenance intervals may vary according to the operation hours and operation condition and needs special interest of the operator CAUTION Be careful not to cause any damage to pump Keep in mind the following while pump is in operation after air has come into pipe line and actuator gallery If necessary repair or replace actu...

Page 698: ...raulic oil will change its property or quality hour by hour largely on every 500 hours of operation Check for any unusual contamination of the filter every day until the first filter has been replaced after beginning operation 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 bee...

Page 699: ...nd winter seasons Replace all hydraulic fluid Be careful not to allow any foreign objects to enter the hydraulic system Keep the inside of the actuator oil tank clean Refill oil through the filter HYDRAULIC FLUID LEAKAGE CHECK 1 Check every day after starting operation 2 When the viscosity is over the operating range due to the low hydraulic fluid temperature warm up the motor by operating the mot...

Page 700: ...ater in hydraulic fluid Adjust rotation speed Mechanical damage bearing etc Check all major components Replace damaged parts or replace pump Adjust rpm Clean circuit Replace oil Insufficient Outflow Rate Input axle rpm is low Check input axle rpm Adjust rotation speed Abnormally high hydraulic oil temperature Check oil temperature Stop operation and check after oil temperature has cooled Increasin...

Page 701: ...l vibration Check pilot line for foreign objects Check slipping of the control valve due to foreign objects Replace relief valve Remove foreign objects Repair or replace damaged parts Poor control valve performance Abnormally High Heat Increasing pump leakage Measure the actuator speed Replace pump Mechanical damage bearing etc Check the source of noise and heat Replace damaged parts Damaged rubbi...

Page 702: ...ar blocks may be used in place of jig as long as end of axle does not touch the work bench Oil Leakage Seal surface packing or O ring damage Check area around leak and for abnormal pressure Replace seal Symptoms Causes Check Remedies Names of Tools Quantity Size Hex Wrench 1 Each 3 6 8 12 6 L 20 Spanner 1 17 22 Plastic Hammer 1 Medium Size Retaining Ring Pliers 1 Internal Retaining Ring Pliers 1 E...

Page 703: ... of equipment 2 Be careful not to strike or drop any parts during disassembly Reminders for Assembly 1 Thoroughly clean all parts 2 Be very careful not to damage any parts or allow any foreign objects to come into the parts being assembled 3 As a rule do not reuse O ring and oil seal DOOSAN recommends to use new O rings and oil seals 4 During assembly always use a torque wrench to tighten all bolt...

Page 704: ...e hex socket head bolts M8 x 30 2 Each by using a 6 mm Allen wrench Gear Pump Disassembly 1 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 2 Remove couplings 3 Remove bushing Figure 9 Figure 10 Figure 11 Figure 12 ...

Page 705: ...Each NOTE Use Allen wrench 12 mm 3 Remove cover while keeping horizontal balance There may be some resistance while removing cover so lightly tap cover with a plastic hammer 4 Remove gasket 5 Remove components from housing 6 Remove two springs and spring seats 7 Remove parallel piston from housing Figure 13 Figure 14 Figure 15 Figure 16 ...

Page 706: ...the axle Axle Removal 1 Remove retaining ring C type 80 using an internal retaining ring pliers 2 Remove oil seal case and O ring by using two screw drivers 3 Tilting plate disassembly 4 Using an Allen wrench 6 mm remove hex socket bolts M8 x 22 4 Each and plate Figure 17 Figure 18 Figure 19 Figure 20 ...

Page 707: ...tside wheel 6 Bearing inside wheel disassembly Use a brass drift 10 and tap the underside of the bearing and remove 7 Remove tilting plate 8 Bearing outside ring disassembly NOTE Perform this disassembly only when necessary Figure 21 Figure 22 Figure 23 Figure 24 ...

Page 708: ...move two spring seats two springs and two parallel pins 5 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 6 Disassembling the two pistons 7 Mark the right and the left for differentiation Figure 25 Figure 26 Figure 27 Figure 28 ...

Page 709: ...e them only when necessary 2 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 3 Disassemble spring seat 4 Disassemble relief valve Remove hex nuts NOTE Disassemble this part only when necessary NOTE Use wrench 24 mm Figure 29 Figure 30 Figure 31 Figure 32 ...

Page 710: ...SP001488 Main Pump Page 30 5 Remove adjusting screws NOTE Be careful not to lose the shim 6 Remove springs 7 Remove spools Figure 33 Figure 34 Figure 35 ...

Page 711: ...lts M8 x 45 4 each 2 Remove side plate backup ring oblong cylindrical ring and gear 3 Remove idle gear 4 Gear pump GSP2 disassembly 5 Using a wrench 6 mm remove hex socket bolts M10 x 90 4 each 6 Remove O rings and filters assembled into the gear pump housing Figure 36 Figure 37 Figure 38 Figure 39 ...

Page 712: ...SP001488 Main Pump Page 32 7 Remove front cover 8 Disassemble the middle body 9 Remove molded O rings 10 Disassemble plate guide and O ring Figure 40 Figure 41 Figure 42 Figure 43 ...

Page 713: ...2 Disassemble drive gear idle gear and side plate Disassemble Solenoid Valves 1 Using an Allen wrench 8 mm remove Allen head bolts M4 x 10 4 each 2 Remove solenoids NOTE Be careful not to drop the push rod Figure 44 Figure 45 Figure 46 Figure 47 ...

Page 714: ...SP001488 Main Pump Page 34 3 Remove spools 4 Remove O rings 5 Remove springs Figure 48 Figure 49 Figure 50 ...

Page 715: ...ly to the moving areas corrosion and abnormal abrasions Measure the gap between the outside diameter of the piston and the inside diameter of the cylinder block and verify that they are within acceptable limits Gap Limit D d 0 050 mm 0 0197 2 Piston Shoe and Piston Check gap between the piston and the piston shoe axle Gap Limit E 0 2 mm 0 0079 3 Axle Check surface condition of the mating area of t...

Page 716: ...ng 6 Solenoid Valves A and B Check the clearance between inside diameter of the block and the outside diameter of the spool Clearance D d 0 015 mm 0 0006 7 Relief Valve Check the clearance between the inside diameter of the cover and the outside diameter of the spool Clearance D d 0 015 mm 0 0006 8 Relief Valve Check the set pressure Set pressure 30 0 2 kg cm2 6 5 l min 100 rpm 427 psi 1 72 gpm 10...

Page 717: ...g Plate 1 Install bearings outside wheel into housing 2 Coat backside of the plate with grease and install tilting plate 3 Install tilting plate into housing Figure 58 Figure 59 Figure 60 Reference Number Description 1 Shiny Surface 2 Front Face 3 Rear Face Figure 61 ...

Page 718: ...ngs both inside and outside wheels 5 Install seal and O rings 6 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 62 Figure 63 Figure 64 ...

Page 719: ... key groove to position the bearing near the end of the housing 2 Lightly coat the O rings with grease and install into housing 3 Place oil seal flat to the housing surface Prepare oil seal by coating with grease in advance 4 Install retaining rings to hold axle in place Figure 65 Figure 66 Figure 67 Figure 68 ...

Page 720: ...er 8 Coat inside of the guides with grease 9 Install guides between retainer and cylinder block and then insert pistons into cylinder block 10 Install rotary group assembly into spool axle NOTE While assembling coat the slipping face of the piston shoe and the contact points of the control plate cylinder block with grease Figure 69 Figure 70 Figure 71 Figure 72 ...

Page 721: ...ng bores with grease before assembling 2 Install two springs both internal and external 3 Install spring seat and insert control spring 4 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 73 Figure 74 Figure 75 Figure 76 ...

Page 722: ...oat bolts with Loctite 270 before tightening NOTE Tightening Torque 55 69 Nm 5 6 7 0 kg m 40 5 50 5 ft lb 6 Install pistons 7 Engage a spring and a cone type plate spring 2 units Figure 77 Figure 78 Figure 79 Figure 80 Reference Number Description 1 Assembling Direction 2 Cone Type Plate Spring ...

Page 723: ...TE Tightening Torque 350 470 Nm 36 48 kg m 260 347 ft lb 9 Coat parallel pins with grease and insert into cylinder 10 Coat rear side of control plate with grease and align plate with key groove in cover and install onto block Figure 81 Figure 82 Figure 83 ...

Page 724: ...SP001488 Main Pump Page 44 Assembling Relief Valve 1 Install spools 2 Insert springs into spool bore 3 Insert shim s into adjusting bolt 4 Insert adjusting bolt Figure 84 Figure 85 Figure 86 Figure 87 ...

Page 725: ...Assembling of pickings 7 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 8 Install cover M14 x 40 2 each M14 x 75 1 each NOTE Torque 150 180 Nm 15 18 kg m 108 50 130 ft lb 9 Install O rings in cover Figure 88 Figure 89 Figure 90 Figure 91 ...

Page 726: ...1 Install couplings at the end of the main pump axle 12 Assemble main pump and gear pump 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 Figure 92 Figure 93 Figure 94 Figure 95 ...

Page 727: ...TE Be careful not to reverse the directions of intake and exhaust sides 2 Install drive axle and idle gear on the side plate 3 Install drive axle idle gear and side plate Figure 96 Reference Number Description 1 Intake Side 2 Discharge Side 3 Direction of Inserting Square Rings Figure 97 Figure 98 Figure 99 ...

Page 728: ...en insert them into plate 5 Assemble plate guide and O ring 6 Assemble two plates Be careful not to reverse the directions of the intake and exhaust sides Figure 100 Figure 101 Reference Number Description 1 Face With Large Radius 2 Guide Figure 102 Figure 103 ...

Page 729: ...Page 49 Main Pump 7 Install square ring 8 Insert two alignment pins into front cover 9 Install front cover Figure 104 Reference Number Description 1 Intake Side 2 Discharge Side Figure 105 Figure 106 Figure 107 ...

Page 730: ... Pump G1 1 Insert drive gear into housing 2 Insert idle gear 3 Coat square rings with grease Assemble making certain the backup ring is in place 4 Install side plate assembled in step 12 into housing Figure 108 Figure 109 Figure 110 Figure 111 ...

Page 731: ...ligning pins in the middle housing 6 Install O ring into middle housing 7 Assemble the two middle housings 8 Install socket head bolts to secure housing NOTE Tightening Torque 29 Nm 3 kg m 21 70 ft lb Figure 112 Figure 113 Figure 114 Figure 115 ...

Page 732: ... Place the Gear Pump GSP2 on its side and install coupling to the end of axle 11 Assemble two Gear Pumps GSP2 and G1 12 Install Allen head bolts to secure the two gear pumps GSP2 and G1 NOTE Tightening Torque 59 Nm 6 kg m 43 40 ft lb Figure 116 Figure 117 Figure 118 Figure 119 ...

Page 733: ...SP001488 Page 53 Main Pump 13 Install O ring and filter in the front housing Assembling Solenoid Valves 1 Insert springs 2 Insert spools 3 Install O rings Figure 120 Figure 121 Figure 122 Figure 123 ...

Page 734: ...lenoid in place M4 x 10 4 each NOTE Tightening Torque 3 4 Nm 0 35 0 45 kg m 2 53 3 25 ft lb 6 Install O ring 7 Mount solenoid assembly onto main pump using socket head bolts M4 x 10 4 each NOTE Tightening Torque 28 35 Nm 2 9 3 6 kg m 21 26 ft lb Figure 124 Figure 125 Figure 126 Figure 127 ...

Page 735: ...SP001640 Page 1 Remote Control Valve Work Lever Joystick SP001640 REMOTE CONTROL VALVE WORK LEVER JOYSTICK SP001640 Remote Control Valve Work Lever Joystick Edition 1 ...

Page 736: ...SP001640 Remote Control Valve Work Lever Joystick Page 2 MEMO ...

Page 737: ... 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 9 Assembly Method 12 ...

Page 738: ...SP001640 Remote Control Valve Work Lever Joystick Page 4 MEMO ...

Page 739: ...s 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 740: ...Control Valve Work Lever Joystick Page 6 STRUCTURE DIAGRAM III 25 III 24 21 22 II A 17 II 15 20 II 16 29 I A 9 I A 8 30 5 1 2 4 3 I 6 13 I 7 1 B 10 I B 11 I 12 II 14 19 II B 18 23 III 26 III 28 III 27 FG010350 Figure 1 ...

Page 741: ...2011 X 13 Spring 4 J96C2001 O II A Plug Kit Port 1 3 JA7L4013 O II B Plug Kit Port 2 4 JA7L4014 O II 14 Plug 4 JA2M5017A X II 15 Rod Seal 10 16 4 5 N B R 4 C1 1008 X II 16 O Ring 4D P20 FKM 4 PO 020 F X II A 17 Push Rod Port 1 3 J95C1009 X II B 18 Push Rod Port 2 4 J96C1001 X 19 Plate 1 JA1G1002 O 20 Boot 1 J97A5018 O 21 Joint Ass y 1 J95C1012 O 22 Swash Plate 1 J97A5016 O 23 Hex Nut 1 J95C1014 O ...

Page 742: ...kgf cm 2 Secondary pressure Single Operating Torque Secondary pressure Single Operating Torque Operating torque kgf cm Secondary pressure kgf cm 2 Operating torque kgf cm Push ROD Stroke mm PORT 1 3 40 0 2 4 6 7 6 5 1 1 0 2 4 6 8 9 8 5 1 1 0 6 6 16 5 21 8 40 40 0 6 6 17 4 22 9 40 Push ROD Stroke mm PORT 2 4 Figure 2 P T 1 3 2 4 FG011413 Figure 3 ...

Page 743: ...SEMBLY TOOL DISASSEMBLY METHOD 1 Separate the HANDLE KIT III from the HEX NUT 23 2 Separate the BOOT 20 from the SWASH PLATE 22 Part no Tool Specification Remarks 21 Driver type 29 Driver type Small size 22 Spanner 27 mm 22 Spanner 22 mm III 26 Spanner 13 mm Figure 4 Figure 5 ...

Page 744: ...e the HEX NUT 23 from the SWASH PLATE 22 and remove the SHAWH PLATE 22 4 Separate the JOINT ASS ØY 11 from the BODY 1 5 Remove the PLATE 19 and separate the PLUG KIT II A II B from the BODY 1 6 Separate the BUSHING 29 from the BODY 1 Figure 6 Figure 7 Figure 8 Figure 9 ...

Page 745: ...SP001640 Page 11 Remote Control Valve Work Lever Joystick 7 Separate the SPOOL KIT I A I B from the BODY 1 8 Separate SPRING 13 from the BODY 1 Figure 10 Figure 11 Figure 12 Figure 13 ...

Page 746: ...3 to the BODY 1 2 Assemble the SPOOL KIT I A I B Assembly order 3 Assemble the SPOOL KIT I A I B BODY 1 Figure 14 Figure 15 Figure 16 SPOOL KIT I A SPOOL I 6 SHIM I 7 SPRING I A 8 SPRING SEAT I A 9 STOPPER I 12 SPOOL KIT I B SPOOL I 6 SHIM I 7 SPRING I B 10 SPRING SEAT I B 11 STOPPER I 12 Figure 17 ...

Page 747: ...lve Work Lever Joystick 4 Install the BUSHING 29 on the BODY 1 5 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 18 Figure 19 Figure 20 Figure 21 ...

Page 748: ... Lever Joystick Page 14 6 Install the PLUG KIT II A II B on the BODY 1 7 Install the PLATE 19 8 Assemble the BODY 1 to the JOINT Ass y 21 9 Apply enough grease on the PUSH ROD and JOINT Ass y part Figure 22 Figure 23 Figure 24 Figure 25 ...

Page 749: ...ntrol Valve Work Lever Joystick 10 Insert the SWAH PLATE 22 and assemble the HEX NUT 23 11 Use the spanner to fixate the HEX NUT 23 firmly to the BODY 1 12 Install the BOOT 20 on the SWASH PLATE 22 Figure 26 Figure 27 Figure 28 ...

Page 750: ...SP001640 Remote Control Valve Work Lever Joystick Page 16 13 Assemble the HANDLE KIT III to the HEX NUT 23 Insert the wire in the BUSHING 29 Figure 29 Figure 30 ...

Page 751: ...SP001490 Page 1 Dozer Valve SP001490 DOZER VALVE SP001490 Dozer Valve Edition 1 ...

Page 752: ...SP001490 Dozer Valve Page 2 MEMO ...

Page 753: ...ble 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 ...

Page 754: ...SP001490 Dozer Valve Page 4 MEMO ...

Page 755: ...ety 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX55 50001 and Up DX60R 50001 and Up ...

Page 756: ...SP001490 Dozer Valve Page 6 STRUCTURE DIAGRAM FG010372 23 22 21 19 15 18 17 II 10 II 12 4 2 1 24 IV 3 I 6 I 7 I 8 I 5 I 9 II 11 II 13 14 16 20 Figure 1 ...

Page 757: ...RFORMANCE SPECIFICATION HYDRAULIC PRESSURE CIRCUIT DIAGRAM FG011414 Push ROD Stroke mm Secondary Pressure Operating Torque 2 Secondary Pressure kgf cm Operating Torque kgf cm 0 2 4 6 22 3 0 Figure 2 P T 1 2 FG011415 Symbol Figure 3 ...

Page 758: ...I 9 Stopper 2set AJV12D106 X II Plug Kit JA6J8011 O II 10 Plug 2 J96H2007 X II 11 Rod Seal DYR 10 N B R 2 RSY 10 X II 12 O ring P14 N B R 2 po 014 X II 13 Push Rod 2 J96H2008 X 14 Cover 1 J96H2009 O 15 Wrench Bolt M6 35L SCM440 2 WBM0635 O 16 Guide 1 J96H2010 O 17 Pin 1 J96H2011 O 18 Socket Bolt M5 15L 2 J96H2012 O 19 Nut M5 SCM440 2 HNM05 O 20 Lever 1 JA2C1001 O 21 Spring Pin ø3 18L 1 SP0318 O 22...

Page 759: ... AND ASSEMBLY TOOL DISASSEMBLY 1 Separate the BOOT 22 2 Remove the PIN 17 and separate the LEVER 20 Part no Tool Specification Remarks 15 Torque wrench L35 mm 150 Kgf cm2 17 L wrench 10 mm 18 L wrench 15 mm 19 Spanner 8 mm Figure 4 Figure 5 ...

Page 760: ... 10 3 Loosen the fixated WRENCH BOLT 15 and separate the COVER 14 4 Separate the PLUG KIT II from the BODY 1 5 Separate the SPOOL KIT I from the BODY 1 6 Separate the SPRING 4 from the BODY 1 Figure 6 Figure 7 Figure 8 Figure 9 ...

Page 761: ...SP001490 Page 11 Dozer Valve 7 Separate the PLUG 2 from the BODY 1 Figure 10 ...

Page 762: ...e PLUG 2 to the BODY 1 2 Assemble the SPRING 4 to the BODY 1 3 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 4 Assemble the SPOOL KIT I to the BODY 1 Figure 11 Figure 12 Figure 13 Figure 14 ...

Page 763: ... Page 13 Dozer Valve 5 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 6 Assemble the PLUG KIT II to the BODY 1 Figure 15 Figure 16 Figure 17 ...

Page 764: ...zer Valve Page 14 7 Assemble the COVER 14 to the BODY 1 8 After assembling the LEVER20 20 and GUIDE 16 then install it on the BODY 1 and fixate the assemble with the PIN 17 Figure 18 Figure 19 Figure 20 Figure 21 ...

Page 765: ...SP001490 Page 15 Dozer Valve 9 Adjust the gap between the GUIDE 16 and PUSH ROD II 13 10 Assemble the BOOT 22 Figure 22 Figure 23 ...

Page 766: ...SP001490 Dozer Valve Page 16 ...

Page 767: ...SP001641 Page 1 Travel Contorl Valve SP001641 TRAVEL CONTORL VALVESP001641 Travel Contorl Valve Edition 1 ...

Page 768: ...SP001641 Travel Contorl Valve Page 2 MEMO ...

Page 769: ... 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 9 Disassembly 10 Assembly 15 Troubleshooting 21 General Caution 21 Troubleshooting and Resolution 21 ...

Page 770: ...SP001641 Travel Contorl Valve Page 4 MEMO ...

Page 771: ...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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 772: ...gure 1 Reference Number Description 1 Casing 1 2 Casing 2 3 RO Plug 4 PT Plug 5 Spool 6 Washer 7 Washer 8 Spring 9 Spring 10 Spring Seat 11 O ring 12 Spring 13 Piston 14 Push Rod 15 Socket Bolt 16 O ring 17 Plug 18 Cover 19 Packing 20 Grease Cap 21 Steel Ball 22 Bush 23 Cam Shaft 24 Bellows 25 Screw 26 Cam 27 O ring 28 O ring Reference Number Description ...

Page 773: ...AULIC PRESSURE CIRCUIT DIAGRAM Secondary pressure Operating Torque Secondary Pressure kgf cm 2 Push ROD Stroke mm FG013468 Operating Torque N m 10 75 6 08 5 70 4 35 1 95 0 7 2 7 3 2 0 0 1 2 3 5 10 12 0 9 0 6 0 3 0 2 0 1 0 0 54 0 1 Figure 2 FG013469 1 2 3 4 P T Figure 3 ...

Page 774: ...commended Loctite 241 Sand paper Oil stone 1000 2000 Vice Grease spoon Tool Product number Product name Size Tightening Torque Remarks Torque Wrench 15 Socket Bolt M6 170 15 25 Screw M6 83 10 3 Po Plug PF1 4 300 20 4 Pt Plug NPTF1 16 70 10 Driver 19 Nhu Packing Hammer 22 Bush 23 Cam Shaft Special tool 22 Bush 2 20 32 3 0 12 0 25 0 40 10 0 20 0 25 FG010491 Figure 4 ...

Page 775: ...valves Spool Exchange when the sliding part is worn off 10um or above compared to non sliding part Leakage level is expected to be same Push rod Exchange when the top part is worn off 1mm or above Controller clearance Exchange when the clearance of cam cam shaft and controller bush is 2mm or above from wear off When the part or bolt is loose or when there is a gap tighten according to regulated to...

Page 776: ...on the part 3 Protect the parts from dust before the assembly Also check all surface of the valve before the assembly to check for scratch dent and wear off Exchange any suspicious parts Disassembly procedure 1 Clean the pedal valve with the cleaning solvent Block each port with the blind plug 2 After separating the bottom of the bellows 24 from the cover 18 pull it up to take it off 3 Use the tor...

Page 777: ...crew the screws 25 NOTE Be careful because the loosening torque can be high from the applied Loctite 242 6 Align the rot to one end of the cam shaft 23 and lightly use the hammer to disassemble it 7 Disassemble the cam 26 from the cover 18 as the assembly with the steel ball 21 and bush 22 attached Figure 7 Figure 8 Figure 9 Figure 10 ...

Page 778: ... 12 8 Disassemble the casing 2 2 from the casing 1 1 9 Disassemble the push rod 14 from the plug 17 10 Disassemble the plug 17 from the casing 2 2 11 Disassemble the grease cap 20 from the plug 17 Figure 11 Figure 12 Figure 13 Figure 14 ...

Page 779: ... 19 from the plug 17 Disassemble the dust seal with a small screw driver 13 Disassemble the piston 13 from the casing 2 2 14 Disassemble the spring 12 from the casing 2 2 15 Disassemble the pressure drop valve sub assembly from the casing 1 1 Figure 15 Figure 16 Figure 17 Figure 18 ...

Page 780: ...g 8 from the casing 1 1 17 Disassemble the O ring 11 28 from the casing 1 1 18 Press the spring sheet 10 down and disassemble it from the spool 5 19 Disassemble the spring 9 washer 7 and washer 6 from the spool in this order Figure 19 Figure 20 Figure 21 Figure 22 ...

Page 781: ...nged with a new product 4 When exchanging the O ring or dust seal NHU PACKING be careful not to damage the part When assembling the part apply a small amount of grease on the O ring so that the part does not come off 5 Apply the grease even when assembling a small part so that the part does not come off 6 Tighten the bolt according to the Tightening torque table Measure the tightening torque with ...

Page 782: ... 1 Assemble the sub assembled pressure drop valve assembly as shown above NOTE Assemble to its original location NOTE When installing the pressure drop valve sub assembly be careful not to hit the bottom part of the spool to the corner part of the casing Figure 25 Figure 26 Figure 27 Be careful of casing corner FG011407 Figure 28 ...

Page 783: ...le the O ring 16 on the plug 17 7 Assemble the dust seal 19 on the plug 17 NOTE Be careful of the direction of the dust seal during the assembly NOTE Apply a thin layer of grease on the dust seal before the assembly 8 Insert the push rod 14 to the plug 17 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 ...

Page 784: ...asing 2 2 10 Assemble the grease cap 20 on the plug 17 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 12 Put the steel ball 21 on the cam 26 and user the hammer to press it in Figure 34 Figure 35 Figure 36 Figure 37 ...

Page 785: ...e surface of the hexagonal hole set and tighten it according to the regulated torque 15 Assemble the casing 2 2 on the casing 1 1 16 Apply the grease on the top of the push rod 14 and top of the plug 17 NOTE When applying the grease use the spoon made of soft material so that it does not damage the surface of the push rod and plug Figure 38 Figure 39 Figure 40 Figure 41 ...

Page 786: ... the bellows 24 to the groove of the cam and insert the bottom of the screw into the groove of the cover NOTE When inserting the bottom of the bellows to the groove of the cover apply the rust oil on the internal part NOTE When the bellows is not inserted properly or straight the vibration damper and rust prevention function will significantly deteriorate Figure 42 Figure 43 ...

Page 787: ... can always cause leakage Troubleshooting and Resolution Symptom Cause Resolution When 2nd pressure does not increase 1 1st pressure is low 2 Damage in 2nd pressure setting spring 3 Excessive gap between spool and casing 4 Clearance in controller 1 Adjust 1st pressure 2 Exchange with new part 3 Exchange the spool casing assembly 4 Disassemble and repair or exchange the controller part When 2nd pre...

Page 788: ...SP001641 Travel Contorl Valve Page 22 ...

Page 789: ...SP001073 Page 1 Pedal Valve SP001073 PEDAL VALVE SP001073 Pedal Valve Edition 1 ...

Page 790: ...SP001073 Pedal Valve Page 2 MEMO ...

Page 791: ...SP001073 Page 3 Pedal Valve 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 ...

Page 792: ...SP001073 Pedal Valve Page 4 MEMO ...

Page 793: ...dations 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 Remember that ultimately safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX27Z 5001 and Up DX35Z 5001 and Up DX60R 50001 and Up ...

Page 794: ...rence Number Description 1 Body 2 Plug 3 O ring 4 Spool 5 Spring Seat 6 Spring 7 Spring Seat 8 Stopper 9 Spring 10 Plug 11 O ring 12 Rod Seal 13 Push Rod 14 Cover 15 DU Bush 16 Wrench Bolt 17 Cam 18 Pin 19 Adjust Screw 20 Socket Bolt 21 Bellows Reference Number Description ...

Page 795: ...ND MATERIALS PUSH ROD STROKE mm SECONDARY PRESSURE kgf cm 2 40 0 7 2 7 3 5 30 2 74 3 OPERATING TORQUE kgf cm Operating Torque Secondary Pressure FG008547 Figure 2 P T 1 2 SYMBOL FG008548 Figure 3 No Tool Standard Remark 2 L Wrench 10 mm 16 L Wrench 5 mm 19 L Wrench 3 mm 20 L Wrench 2 5 mm ...

Page 796: ...lve Page 8 DISASSEMBLY 1 Remove Bellows 21 from cover 14 and cam 17 2 Remove cam 17 from cover 14 3 Loosen wrench bolt 16 to remove cover 14 from body 1 4 Remove flug kit from body 1 Figure 4 Figure 5 Figure 6 Figure 7 ...

Page 797: ...SP001073 Page 9 Pedal Valve 5 Remove spool kit from body 1 6 Remove spring 9 from body 1 7 Remove plug 2 from body 1 Figure 8 Figure 9 Figure 10 ...

Page 798: ...y 1 2 Install spring 9 into body 1 3 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 4 Install four spool kit assemblies into body 1 Figure 11 Figure 12 Figure 13 Figure 14 ...

Page 799: ...emblies They should be assembled in same way The assemble order is plug 10 rod seal 12 o ring 11 and push rod 12 6 Install plug kit into body 1 7 Install DU bush into cover 14 8 Tighten wrench bolt 16 to install cover 14 into body 1 Figure 15 Figure 16 Figure 17 Figure 18 ...

Page 800: ...ew 19 socket bolt 20 into cam 17 10 Install cam 17 into the cover 14 Holding down the cam 17 insert the pin 18 from outside 11 Set the cap 17 balance by the L wrench 12 Install bellow 21 from cover 14 and cam 17 Figure 19 Figure 20 Figure 21 Figure 22 ...

Page 801: ...SP001073 Page 13 Pedal Valve 13 Completd Assembly Figure 23 ...

Page 802: ...SP001073 Pedal Valve Page 14 ...

Page 803: ...SP001692 Page 1 Hydraulic Schematic SP001692 HYDRAULIC SCHEMATICSP001692 1Hydraulic Schematic Edition 1 ...

Page 804: ...SP001692 Hydraulic Schematic Page 2 MEMO ...

Page 805: ...SP001692 Page 3 Hydraulic Schematic Table of Contents Hydraulic Schematic Safety Precautions 5 Applicable Models 5 DX60R 7 ...

Page 806: ...SP001692 Hydraulic Schematic Page 4 MEMO ...

Page 807: ...ollow 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 808: ...SP001692 Hydraulic Schematic Page 6 ...

Page 809: ...ID PB P2G P1G A2 A1 A3 AC P0 CUF OFF 2 SPEED T R2 R1 VALVE Pb7 Pa6 B1 B2 SH Pa11 Pb11 A2 A1 Pb1 Pb6 BL Pi1 Pl1 Pa3 2 1 3 LEFT RIGHT 3 SWING 5 6 7 DUMP 1 2 CROWD ARM 4 Pa7 Pb3 Pa1 4 Pb2 Pa2 8 CROWD 3 DUMP BUCKET 1 BOOM 4 DOWN 2 UP Pa7 Pb7 OPTION ACCUMULATOR Pb3 T1 Pb4 Pp Pb5 Pb6 Pl1 A3 Pa3 A4 Pa4 B4 P1 P2 Pa5 A5 B5 B6 Pa6 A6 LEFT JOY STICK AUX Pb8 Pb9 R2 RIGHT JOY STICK Pb10 Pb11 BOOM2 A7 B7 A8 Pa8...

Page 810: ......

Page 811: ...1Electrical System ...

Page 812: ......

Page 813: ...SP001687 Page 1 Electrical System SP001687 ELECTRICAL SYSTEMSP001687 Electrical System Edition 1 ...

Page 814: ...SP001687 Electrical System Page 2 MEMO ...

Page 815: ...ument Panel 17 Function Check 18 Operation 19 Gauge 19 Warning Lights 20 Circuit Diagram of Instrument Panel 22 Control unit circuit 23 Performance Specification 24 Engine Control System 24 Engine Control Dial 25 Engine Control Circuit Diagram 26 Automatic Deceleration Control Auto Idle Control 27 Engine Overheat Protection System 28 Engine Control Unit 29 Control Failure Detection 30 Flashing pat...

Page 816: ...41 Temperature Level Control And Display 42 Weight of R134a Gas Used in Machines 43 Refrigerant System Repairs 44 Refrigerant Safe Handling Procedures 44 Repair and Replacement Procedure 45 Refrigerant Recovery 47 Vacuuming Refrigerant System 47 Leakage Check 49 Refrigerant Charging 49 Inspecting System for Leakage 51 Troubleshooting 52 Refrigerant Pressure Check 52 ...

Page 817: ...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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up ...

Page 818: ...SP001687 Electrical System Page 6 ...

Page 819: ...fier The electric wiring used in the system is easily identifiable by the insulator color The color symbols used in the slectric system are listed in the following chart Electrical Wire Color NOTE RW Red wire with White stripe R Base Color W Stripe Color NOTE 0 85G Nominal sectional area of wire core less insulator 0 85 mm2 Symbol Color W White G Green Or Orange B Black L Blue Lg Light Green R Red...

Page 820: ...for backup 2 B terminal of starter switch No 1 terminal of hour meter 3 No 34 terminal of ECU Engine control unit When the starter switch is in the ON and START positions the current flows from the battery 1 fusible link 3 fuse box 6 starter switch 5 B terminal BR terminal battery relay 2 B terminal which activates the coil of the battery relay and the electric supply system is energized When the ...

Page 821: ...l System 20A 20A 30A FG012303 Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Alternator Reference Number Description ...

Page 822: ...y 11 are closed by the current flow from battery 1 fusible link 3 B terminal of starter switch 6 C terminal 86 terminal of the starter relay 11 85 terminal 20 terminal of ECU 5 ground When the contact point of 30 and 87 of starter relay 11 are connected the pinion gear of the starter 12 is pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter ...

Page 823: ... 2 3 4 5 6 7 8 9 10 11 12 13 14 14 FG011497 STARTER SWITCH CONNECTION PST TML OFF ON START B BR R1 R2 C ACC Figure 2 STARTER CIRCUIT Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Fuse Box 6 Starter Switch 7 Main Relay 8 Rack Actuator Relay 9 Engine Control Unit 10 Fuel Injection Pump 11 Starter Relay 12 Starter 13 Engine Emergency Stop Switch 14 Diode Re...

Page 824: ...the starter RACK ACTUATOR SPEED SENSOR CSD COIL ENGINE 34 30 86 47 45 13 9 2 GND A 36 28 43 42 33 87 85 24 87a 3 87 1 85 86 87a 30 18 GND RPM 41 19 07 20 08 E BR B A C R1 B BR R2 ACC 86 30 85 87 A B C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 FG011497 STARTER SWITCH CONNECTION PST TML OFF ON START B BR R1 R2 C ACC Figure 3 START CIRCUIT Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Li...

Page 825: ...trols the preheat relay 11 and current flows from the 44 terminal of engine control unit 9 86 terminal of preheat relay 11 85 terminal of preheat relay 11 ground This current flow causes the coil in preheat relay 11 to be activated closing contacts When the contacts of the preheat relay 11 are closed the heating coils of the air heater 12 is heated by current flowing from battery 1 battery relay 2...

Page 826: ... 12 13 23 L4 15 STARTER SWITCH CONNECTION PST TML OFF ON START B BR R1 R2 C ACC FG011498 Figure 4 ENGINE PREHEAT CIRCUIT Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Fuse Box 6 Starter Switch 7 Main Relay 8 Rack Actuator Relay 9 Engine Control Unit 10 Fuel Injection Pump 11 Preheat Relay 12 Air Heater 13 Engine Coolant Temperature Sensor 14 Diode 15 Ins...

Page 827: ...relay 8 to fuel injection pump 10 stops This stops fuel from being injected into the engine thus stopping the engine In the event that the engine can not be shut down using the starter switch 6 an emergency stop switch 13 is provided to shut down engine RACK ACTUATOR SPEED SENSOR CSD COIL ENGINE 34 30 86 47 45 13 9 2 GND A 36 28 43 42 33 87 85 24 87a 3 87 1 85 86 87a 30 18 GND RPM 41 19 07 20 08 E...

Page 828: ...7 circuit breaker 4 battery relay 2 battery 1 The alternator also supplies electric current to other electric components 8 F E L IG E IG P L B BATT E BR 1 B R1 BR 4 6 ACC C R2 B 2 A 3 30A 14 15A 10 15A 9 20A 20A 20A 11 13 12 18 19 20 16 10A 10A 10A 15 10A 10A 10A 17 10A 10A 1 2 6 3 5 4 7 8 5 7 STARTER SWITCH CONNECTION PST TML OFF ON START B BR R1 R2 C ACC FG011499 Figure 6 CHARGING CIRCUIT Refere...

Page 829: ...Figure 7 Reference Number Description 1 Engine Coolant Temperature Gauge 2 Fuel Gauge 3 Engine Oil Pressure Warning Light 4 Charge Warning Light 5 Air Cleaner Clogging Warning Light 6 Preheat Indicator Light 7 Engine Coolant Temperature Warning Light 8 Fuel Level Warning Light 9 High Travel Speed Indicator Light 10 Working Light Indicator Light 11 Water in Fuel Warning Light 12 Quick Clamp Indicat...

Page 830: ...s 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 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 28 23 24 25 26 27 FG011463 Figure 8 ...

Page 831: ...e Function Display Sensor Specification Input Terminal Input Specification Engine Coolant Temperature 2 50 C Over 188 2Ω 67 C 102Ω 105 C 32Ω 125 C below 19 8Ω Fuel Quantity 3 Empty Over 90Ω 1 2 38Ω Full below 10Ω AXO0280L White Red Red White AXO0290L ...

Page 832: ...charging L terminal output of alternator drops below 5V Under normal condition it will light up before engine start up and shut off once engine is running Air Cleaner 6 Lights up when air cleaner is clogged Preheating 15 It lights during preheating and turns OFF after completion of preheating Engine Coolant Temperatur e 10 Lights up when coolant temperature increase over 110 C The warning buzzer s...

Page 833: ...s increased in the water seperator Quick Clamp 14 Lights up when the quick clamp switch turns ON Engine Check 20 It lights in case of failure in engine system Overload warning 13 Warning buzzer also starts when boom pressure voltage is about 1 9 while overload warning switch is ON Description Symbol Input Terminal Operation Remarks FG010190 HB4O2003 FG010520 FG010192 CHECK FG000045 FG000253 ...

Page 834: ...6 7 L5 L3 5 L18 9 3 4 5 BR FUEL GAUGE ILLUMINATION W T GAUGE 3 U 4 F 2 U W 1 B WATER SEPERATOR L16 11 2 5 15 14 13 12 6 9 10 11 7 8 4 3 2 1 FG011500 Figure 9 Reference Number Description 1 Battery 2 Battery Relay 3 Circuit Breaker 4 Fuse Box 5 Instrument Panel 6 Control Unit 7 Engine Coolant Temperature Sensor 8 Fuel Sensor 9 Engine Oil Pressure Switch 10 Water In Fuel Warning Switch 11 Air Cleane...

Page 835: ... 4 1 27 W T GAUGE ILLUMINATION FUEL GAUGE 2 U U F W 3 4 1 BR E A B 7 8 SIG 6 2 ECU 5 15 7 6 8 10 4 3 2 1 9 14 11 12 13 FG011501 Figure 10 Reference Number Description 1 Battery 2 Battery Relay 3 Circuit Breaker 4 Fuse Box 5 Instrument Panel 6 Control Unit 7 Engine Coolant Temperature Sensor 8 Engine Oil Pressure Switch 9 Alternator 10 Pilot Buzzer 11 Quick Clamp Select Switch 12 High Speed Select ...

Page 836: ...ot buzzer turned on 4 Starter switch ON and Alternator L terminal 6 5 1V Below L1 turned on 5 6 5 1V Over L1 turned off 6 Alternator L terminal 6 5 1V over state Engine oil pressure switch ON L2 turned on and pilot buzzer will be turned on after approximately 8 seconds 7 Engine coolant temperature 110 C over Pilot buzzer will be turned on immediately 8 Overload warning switch ON and Pressuresensor...

Page 837: ...l vary from 5V supplied from the engine throttle controller as shown in the graph 2 1 1 1 VIEW POTENTIOMETER BOTTOM 1st STEP 10 10 7th STEP 13th STEP CCW MECHANICAL STOP CW MECHANICAL STOP 2 3 2 3 1 2 3 4 2 5V 1 0V 4 0V 1ST 2nd 7th 12th 13th CW STOP CCW STOP 5 SETUP V 0 HDA6033L Figure 12 Reference Number Description 1 Knob 2 Potentiometer Variable Resistor Reference Number Description ...

Page 838: ... 9 B R1 86 7 30 BR 4 5 6 ACC C R2 B 2 A 3 FG011494 11 Figure 13 Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Fuse Box 6 Starter Switch 7 Main Relay 8 Rack Actuator Relay 9 ECU Engine Control Unit 10 Fuel Injection Pump 11 Engine Control Dial Reference Number Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 ...

Page 839: ...ial setting at start up is with switch in the select position Approximately 4 seconds after this function is selected if all work levers are in the neutral position the ECU compares the automatic reduction signal with the signal set by engine control dial The lower of the two signal is selected the ECU sends a signal to the ECU to control the engine speed The neutral status of the machine is detec...

Page 840: ...erheat warning light in the instrument panel will be turned on and the pilot buzzer sounds simultaneously At this time the engine speed is set a low speed by the ECU When coolant temperature falls below 105 C normal operation will resume Figure 16 Reference Number Description 1 Engine Control Dial 2 Instrument Panel 3 Engine Coolant Temperature Sensor 4 ECU Engine Control Unit 5 Pilot Buzzer Refer...

Page 841: ...N6 6 GND A 87 85 30 86 B R1 BR 6 ACC C R2 87 85 30 86 04 23 06 03 02 17 39 40 120ohm CAN L CAN H 30 25bar 87a 01 07 08 44 34 20 24 12 35 2 3 LOW CW HIGH FG011503 Figure 17 Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Fuse Box 6 Starter Switch 7 ECU Engine Control Unit 8 Instrument Panel 9 Main Relay 10 Rack Actuator Relay 11 EGR Valve 12 Fuel Injection ...

Page 842: ...ailure Engine start signal E8 is on but the engine speed is zero With optional backup speed sensor Backup speed sensor becomes active speed is limited to 1800 min 1 Option can change Backup speed sensor failed Engine stops Without optional backup speed sensor Engine stops Turn key off Always enable 6 Engine speed decreases by 480 min 1 or more in 40 ms 4 Rack position sensor failure Correlation be...

Page 843: ... on 12 Main relay failure Power is not shut off even though main relay is off Engine runs normally Correct failure Or turn key off Defaultto disable 1 6 13 Rack actuator relay failure Low status is detected even through port is off Engine stops Turn key off Always enable 1 7 High status is detected even through port is on 14 Backup accelerator sensor failure Sensor voltage is 4 6V or more or 0 2V ...

Page 844: ...ion can change Turn key off Defaultto disable 3 4 25 Oily water separator alarm Oily water separator switch turns on Engine runs normally Option can change Turn key off Defaultto disable 3 5 26 Coolant temperature high alarm Coolant temperature is 115 C or higher alarm is canceled when Coolant temperature decreases to 110 C Option can change Engine runs normally Correct failure Defaultto disable 3...

Page 845: ...f the engine check lamp are shown in Figure 18 When accelerator sensor failure flashing 5 time and EGR valve failure flashing 1 3 times occur the engine check lamp flashes as shown in Figure 18 When two or more failures have occurred simultaneously the engine check lamp indicates all the failures in order of increasing number of flashes cyclically On Off On Off Power on 2s 3s 0 5s 0 5s 3s On repea...

Page 846: ...SP001687 Electrical System Page 34 FUEL INJECTION PUMP Figure 19 ...

Page 847: ...SP001687 Page 35 Electrical System EGR VALVE Figure 20 ...

Page 848: ...m Page 36 REFRIGERANT CIRCULATION 1 2 3 4 5 6 HBOI020L 7 Figure 21 Reference Number Description 1 Evaporator 2 Expansion Valve 3 Condenser 4 Condenser Fan 5 Compressor 6 Blower Fan 7 Receiver Dryer Reference Number Description ...

Page 849: ...ir surrounding the evaporator creating a cooling effect and changes from the gas to the liquid state The refrigerant once again flows into the compressor in the gaseous state and the process is repeated Shading Temperature Refrigerant State High High pressure Gas High High pressure Liquid Low Low pressure Liquid High High pressure Gas Liquid Low Low pressure Gas CAUTION Refrigerant gas is pressuri...

Page 850: ... LOW PRESS CUT OFF CUT OFF HIGH PRESS 30 86 85 87 87a M A B E BR 7 15 16 17 18 8 6 5 4 1 11 9 3 2 12 13 14 10 FG010308 Figure 22 Reference Number Description 1 Battery 2 Battery relay 3 Circuit breaker 4 Fusible link 5 Fuse box 6 Light switch 7 AC panel 8 AC unit 9 Compressor 10 Condenser fan 11 Receiver dryer 12 Blower relay 13 Compressor relay 14 Condenser fan relay 15 Air flow control motor A 1...

Page 851: ...1507 Air flow control motor A Air flow control motor C Blower motor Air flow control motor B 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 Open Close Close Open Open Open Open ...

Page 852: ...SP001687 Electrical System Page 40 Air Flow Control Motor Blower Motor Figure 24 Figure 25 ...

Page 853: ...SP001687 Page 41 Electrical System Coolant Flow Control Valve Figure 26 ...

Page 854: ...n Green Green 3 28V 0 2 8 Red Red Green Green Green Green Green 3 11V 0 2 9 Red Red Red Green Green Green Green 2 93V 0 2 10 Red Red Red Green Green Green Green 2 76V 0 2 11 Red Red Red Green Green Green Green 2 59V 0 2 12 Red Red Red Red Green Green Green 2 41V 0 2 13 Red Red Red Red Green Green Green 2 24V 0 2 14 Red Red Red Red Green Green Green 2 07V 0 2 15 Red Red Red Red Red Green Green 1 89...

Page 855: ...1687 Page 43 Electrical System WEIGHT OF R134A GAS USED IN MACHINES Model 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 ...

Page 856: ...charge the system 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 Be careful not to drop the container from a high l...

Page 857: ...ng parts Do not reuse old O rings 8 Use a vacuum pump to evacuate refrigerant system of air 9 When charging the refrigerant system with the engine running do not open the high pressure valve on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose 10 When releasing the high pressure hose after completing the charging process quickly disconnect the hose to minimi...

Page 858: ...FOR AIR LEAKAGE 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 RUN SYSTEM RECOVER REFRIGERANT IN CHARGING HOSE REMOVE REPAIR TOOLS REPAIR HDA6067L Figure 28 ...

Page 859: ...gauge dials indicates 0 kg cm2 0 psi Vacuuming Refrigerant System 1 Vacuuming Procedure NOTE When the A C system has been exposed to the air it must be vacuumed out Perform vacuum process for 30 minutes for complete moisture and air evacuation A Attach the manifold gauges and vacuum pump to the refrigerant system as shown B Turn on the vacuum pump and open both valves C When the low pressure gauge...

Page 860: ...e mounting valve on the container make sure the handle is in the counter clockwise most position with the puncture pin retracted and the mounting disk is in the raised position B Attach the manifold gauge center hose to the valve assembly C Turn the disc in the clockwise direction and securely mount valve onto refrigerant container D Turn the valve handle in the clockwise direction and puncture th...

Page 861: ... leaking tests as described in the proceeding headings NOTE First charge the refrigerant system with 100 g 3 5 ounces of refrigerant with the engine off Then using the manifold gauges as a guide fully charge the system with the engine running When exchanging refrigerant containers press the manifold gauge low side valve to eliminate air from the charging hose 2 Charge the system by opening the man...

Page 862: ...t off engine and close refrigerant supply container adapter valve Disconnect manifold gauge hoses from vehicle CAUTION When charging refrigerant system with the engine running Always keep refrigerant supply container in the upright position Never open the high side pressure valve Gauge Dial Standard Reading High Side Gauge 13 20 kg cm2 185 285 psi Low Side Gauge 1 5 3 5 kg cm2 21 49 psi CAUTION Wh...

Page 863: ...ressor outlet condenser inlet receiver dryer inlet air conditioner unit inlet 2 Low pressure side Compressor inlet air conditioner unit outlet 3 Compressor Compressor shaft area bolt hole area and magnetic clutch area 4 Receiver dryer Pressure switch and plug area 5 Connection valve area Inspect all valve areas Verify all valves are capped to prevent leaking Check for foreign material inside of va...

Page 864: ...ep Inspection Item Remedy 1 Check for traces of refrigerant oil Yes Reassemble using correct tightening torque No Go to next step 2 Using a leak detection device or soapy water check for refrigerant leakage at all major components and joints Yes Repair leaking component No Recharge system to correct pressure 2 High pressure Over 23 kg cm2 327 psi Low pressure Approximately 2 5 3 kg cm2 35 42 psi P...

Page 865: ...1 3 46 9 psi Yes Moisture in system replace receiver dryer No Contaminated system replace expansion valve Replace evaporator core assembly 5 High pressure Over 6 18 kg cm2 85 256 psi Low pressure 500 mmHg Negative Pressure Dial indicator needle unstable Possible Cause Moisture in system has iced up the expansion valve NOTE When the absorbed moisture freezes the pressure readings may look normal Ca...

Page 866: ...ical System Page 54 7 High pressure Over 7 11 kg cm2 100 156 psi Low pressure 4 6 kg cm2 57 85 psi Possible Cause Low refrigerant pressure due to poor compressor compression Inspect and replace compressor if necessary ...

Page 867: ...SP001688 Page 1 Electrical Schematic DX60R DX80R SP001688 ELECTRICAL SCHEMATIC DX60R DX80R SP001688 1Electrical Schematic DX60R DX80R Edition 1 ...

Page 868: ...SP001688 Electrical Schematic DX60R DX80R Page 2 MEMO ...

Page 869: ...SP001688 Page 3 Electrical Schematic DX60R DX80R Table of Contents Electrical Schematic DX60R DX80R Safety Precautions 5 Applicable Models 5 DX60R DX80R 7 ...

Page 870: ...SP001688 Electrical Schematic DX60R DX80R Page 4 MEMO ...

Page 871: ...ow 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up ...

Page 872: ...SP001688 Electrical Schematic DX60R DX80R Page 6 ...

Page 873: ... CLAMP DX60Z OPTION QUICK CLAMP SWITCH 1 0 85B 0 85B 10 7 I 0 85WR 9 0 0 85LR 5 87a 86 30 87 85 BREAKER RELAY 0 85B 11 13 60P 22 9 10 3 5 8 18 19 20 21 7 6 1 16 2 14 15 26 3 1 2 6 4 3 2 0 85B 0 85RL 2B P FUEL PUMP 2WL 41E ADDITIONAL WORKING LAMP OPT 0 85Y WATER VALVE ASS Y 1 25B CIGAR LIGHTER LAMP RELAY 86 30 0 85B 87a 87 85 0 85RG 0 85B CABIN LAMP AUTO IDLE PRESSURE SWITCH AIRCON UNIT 30R 2 0RG 1...

Page 874: ......

Page 875: ...1Attachments ...

Page 876: ......

Page 877: ...SP001642 Page 1 Boom and Arm SP001642 BOOM AND ARM SP001642 1Boom and Arm Edition 1 ...

Page 878: ...SP001642 Boom and Arm Page 2 MEMO ...

Page 879: ...y 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 11 Boom Installation Procedure 11 Start up Procedures 11 ...

Page 880: ...SP001642 Boom and Arm Page 4 MEMO ...

Page 881: ...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 Remember that ultimate safety is your own personal responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up ...

Page 882: ...ns for all mounting pins used on the front attachment 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 A K B H G I D F J C E Figure 1 ...

Page 883: ...0 04 0 29 4 0 284 0 384 1 5 0 09 0 24 4 E Arm Cylinder Head Pin 50 mm 1 97 in 189 mm 7 44 in 0 04 0 20 0 04 0 29 1 5 0 09 0 F Arm Cylinder Rod Pin 50 mm 1 97 in 174 mm 6 85 in 0 04 0 20 0 04 0 29 1 5 0 09 0 G Arm Link Pin 45 mm 1 77 in 286 mm 11 26 in 0 05 0 27 8 0 278 0 348 1 5 0 07 0 22 8 H Arm End Pin 45 mm 1 77 in 285 mm 11 22 in 0 04 0 27 8 0 268 0 368 1 5 0 09 0 22 8 I BucketCylinder Head Pi...

Page 884: ... structure is in line with the lower structure Never rotate the upper structure once the counterweight or front attachment has been removed IMPORTANT Always break down the front attachment by removing outermost sections first the bucket before the arm the arm before the boom Reinstallation of the attachment should begin with the boom and end with the bucket WARNING This procedure is only intended ...

Page 885: ...lings and put a clean plug in the end of each one Use any and all reasonable precautions necessary to avoid introducing dirt or other contaminants into the hydraulic system Wipe down coupling points before disconnecting hydraulic lines and use evaporative type solvent spray cleaner Tag and mark hoses for reassembly if necessary Place a sling under the arm cylinder the cylinder used to extend and r...

Page 886: ...Removal Procedure observing the same precautions Disconnect wiring for work light assemblies and any other accessory lines or connections Locate the sling of the assist crane near the center of gravity optimum lift point for the boom and use the crane to take pressure off the boom foot pin Drive out the pin after disassembling retainers and carefully lift away the boom To maintain stability the co...

Page 887: ...e pin the mounting connection Boom Installation Procedure Before reassembling the attachment make sure to inspect all bushings and pivot points of each section To avoid damaging the seats bushings should never be hammered or chiseled out of their seats Installation is otherwise a reversal of the removal procedures START UP PROCEDURES Once the boom has been serviced it should be lubricated as outli...

Page 888: ...SP001642 Boom and Arm Page 12 ...

Page 889: ...SP001643 Page 1 Bucket SP001643 BUCKET SP001643 1Bucket Edition 1 ...

Page 890: ...SP001643 Bucket Page 2 MEMO ...

Page 891: ...e 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 ...

Page 892: ...SP001643 Bucket Page 4 MEMO ...

Page 893: ... 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 the load Remember that ultimate safety is your own responsibility MODEL SERIAL NUMBER RANGE DX60R 50001 and Up DX80R 50001 and Up ...

Page 894: ...int that bucket adapter is exposed See Figure 1 Figure 2 2 To replace a tooth use a hammer 1 Figure 3 and punch 2 Figure 3 to drive locking pin 4 Figure 4 and locking rubber 3 Figure 4 out of tooth adapter 3 Once worn tooth has been removed use a putty knife to scrape adapter as clean as possible 4 Slide new tooth into position and insert lock washer 5 Insert locking pin into tooth and with a hamm...

Page 895: ...SP001643 Page 7 Bucket X 1 3T T X X FG012221 4 3 Figure 4 X X X X X HFO3043I Figure 5 ...

Page 896: ...the way 3 Remove the old O ring and temporarily install the new O ring 1 Figure 8 onto the bucket boss 2 Make sure that the O ring groove on both the bucket link 4 and boss have been cleaned 4 Realign the arm or link with the bucket pin hole and insert the bucket pin 3 Figure 7 WARNING Due to possibility of flying metal objects always wear safety helmet protective gloves and eye protection when ch...

Page 897: ...of the bucket pin and pull out the pin If the pin sticks and resists normal withdrawal there may be a load on it Raise and lower the arm slightly until the unstressed pin position is located When the pin has been withdrawn move the operating joystick slightly to take weight off the remaining link pin Disassemble the link pin end retainers and pull out the pin Lift the arm away from the bucket so t...

Page 898: ... the bucket pin holes lower and raise the arm and boom and install the bucket pin Reversing the Bucket Follow instructions for Detaching the Bucket and remove both the bucket and link pins Rotate the bucket 180 to change bucket configuration This procedure is greatly simplified if some type of rotating or swiveling support can be used on the ground underneath the bucket Follow instructions for Buc...

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