Disassembly and Asembly of Clutch K1,K2,K3,K4 of Doosan Transmission Part

 This paper introduces the disassembly And assembly of the clutch K1,K2,K3,K4 of Doosan transmission part

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Disassemble Clutch-K1,K2 and K3
NOTE: The following Figures show the disassembly of the clutch K31. The disassembly of the clutches K1 and K2 is analogous.
Squeeze rectangular ring(Figure 150) out.

2. Pull tapered roller bearing from the shaft.
3. Remove opposite tapered roller bearing accordingly, see Figure 151 and Figure 151.(S) Grab sleeve-5873 001057
(S) Grab sleeve(K3-on output side)-5873 001 058
(S) Basic set-5873 001 000

4. Remove running disk, axial needle cage and axial washer.

5.Remove idler gear.

6. Remove both needle bearings and axial bearing(compl.).


7.Squeeze snap ring out and remove plate pack.

8. Preload compression spring, squeeze retaining ring out and remove components.
(S) Assembly aid(K2 and K3)-5870 345085
(S) Assembly aid (K1)-5870 345 086
(S) Set of extemal pliers-5870 900015

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9. Press piston out of the plate carrier, using compressed air.

10. Pry plate carrier from the shaft.
(S) Pry bar-5870345065

Disassemble Clutch-K4
1. Squeeze rectangular ring out and pull tapered roller bearing from the shaft.
2. Remove opposite tapered roller bearing.
(S) Grab sleeve-5873 001057
(S) Basic set-5873 001 000

3. Squeeze retaining ring out and remove plate carrier from the shaft.
(S) Assembly aid-5870345085
(S) Set of extemal pliers-5870 900015

4.Squeeze snap ing out and remove plate pack.

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5. Preload compression spring, squeeze retaining ring out and remove components.
6. Remove piston.
NOTE: The separation of shaft and gear is not possible
(shrink fit).
(S) Assembly aid-5870 345085

Disassemble Input Shaft
1. If necessary, press turbine shaft out of the input shaft.
NOTE: The turbine shaft is axially fixed using a snap ring which wil be destroyed at the pressing out.
2. Squeeze rectangular ring out and pull off the tapered roller bearing.
3. Pull off the opposite tapered roller bearing.
NOTE: The separation of input shaft (1, Figure 164)
and gear(2) is not possible(shrink fit).
(S) Grab sleeve-5873 001 058
(S) Basic set-5873 001 000

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Isuzu Starting Clutch - Removal of KV and KR

          

This paper mainly introduces the disassembly of isuzu clutch - KV and KR

 

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NOTE:The following Figures show the disassembly of the clutch KV.The disassembly of the clutch KR is analogous.

1. Squeeze rectangular ring out.
2. Pull tapered roller bearing from shaft.
3. Remove opposite tapered roller bearing.

2(S) Grab sleeve-5873 001 057

(S) Basic set-5873 001 000


4. Remove plate carrier from shaft.

 

 (S) Hammer-5870 280004

5.Squeeze snap ring out and remove plate pack.

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6. Preload compression spring, squeeze retaining ring out and remove components.
(S) Assembly aid-5870 345 086
(S) Set of external pliers-5870 900015


7.Lift piston using compressed air out of the cylinder bore and remove it.

8.Remove both O-rings.

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9. Squeeze inner retaining ring(shaft) out.
(S) Set of external pliers-5870 900 015

 

 

10. Locate idler gear using separating device(Figure 147) and press it from the shaft(Figure 148).

11. Remove released needle bearing.

12. Squeeze retaining ring out and remove ball bearing.
NOTE: The disassembly of the clutch KR has to be carried out.
(S) Set of internal pliers-5870 900013

Introduction of Doosan Excavator Transmission System(5)

  This article is about the detailed introduction of Doosan excavator transmission system (5)  

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  Remove Hydraulic Control Unit (HGS-94)
and Duct Plate from Gearbox Housing
1. Loosen socket head screws, install two adjusting screws and remove control unit from duct plate.
(S) Adjusting screws-5870 204031

 

2. Remove both gaskets and interme diate plate.
(S) Adjusting screws-5870 204031

3. Loosen socket head screws and hex. nuts and remove ductplate from gearbox housing.
4. Remove flat gasket.
(S) Adjusting screws-5870 204031
Remove and Dismantle Converter Safety Valve
1.Pull converter safety valve out of housing bore.

2. Figure 101, shows required special tool for the dismanting of the converter safety valve.

3. Preload compression spring carefully, remove cylindrical pin(Figure 102) and components(Figure 103).

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1.Remove lock plate and loosen hex.head screws.
2.Remove disk and pry input flange from shaft.

3.Loosen screw connection.
NOTE:Mark radial instalation position of the housing cover.

4., Using lifting device remove cover with converter from transmission.8

(S) Set of eye bols-5870 204002

5. Press input shaft, reap. converter out of the cover (ball bearing).

                                                                     

       6. Squeeze retaining ring out and remove ball bearing.
(S) Set of internal pliers-5870 900013

7. Loosen hex. head screws and remove membrane from    converter.

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8.Loosen hex.head screws and remove input shaft from the membrane.

10.Loosen hex.head screws and remove converter housing.

Introduction of Doosan Excavator Transmission System(4)

  This article is about the detailed introduction of Doosan excavator transmission system (4) 

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   Reassembly NOTE: Check all components for damage and replace if necessary. Before instalation, check free travel of all moving parts in housing. Spools can be exchanged individualy. Oil components before reassemblyaccording to ZF-List of lubricants TE-ML 03.
Insert diaphragms with concave side facing up until seated.
NOTE: Installation position, see arrows.

2. Install components according to Figure 76.
NOTE: Preload compression spring of follow on sitie slides and locate spool provisionaly using cylindrical pins O 5.0 mm (0.1969 in)(assembly aid), See Figure 77.

3. Install two adjusting screws.
4. Assemble gasket(1, Figure 78) and housing cover(Figure
78). Position housing cover uniformly, using adjusting screws, until seated and remove cylindrical pins (assembly aid) again(Figure 78).
NOTE: Pay attention to different housing covers.
5. Install recess  15.0 mm(0.5906 in)
(2, Figure 78), facing spring of pressure reducing valve.
(S) Adjusting screws-5870204036

6. Fasten housing cover using socket head screws.
NOTE: Torque limit 0.56 kg·m(4 ft lb).
(S) Box spanner(Torx TX-27)-5873 042 002

7. Install pressure regulators and attach using fixing plates and socket head screws.
NOTE: Install fixing plate, with claw facing down. Pay attention to radial installation position of pressure regulators, see Figure 81.
NOTE: Torque limit 0.56 kg-m(4 ftlb).
(S) Box spanner (Torx TX-27)-5873 042 002

09

C. Preload compression springs of follow on slides and locate spool provisionally using cylindrical pins
5.0mm(0.1969 in)(assembly aid). See arrows.
D. Install two adjusting screws.
E. Assemble gasket(1, Figure 83) and housing cover, and position them uniformly against shoulder, using adjusting screws.
NOTE: Pay attention to different housing covers, install recess  19.0 mm (0.7480in)(2, Figure 83), facing main pressure valve.
F. Down, fasten housing cover using socket head screws.
NOTE: Torque limit 0.56 kg-m(4 ft lb).
G. Remove cylindrical pins(assembly aid) again.
(S) Adjusting screws-5870 204036
(S) Box spanner(Torx TX-27)-5873 042 002
H. Install pressure regulators and attach using fixing plates and socket head screws.
NOTE: Instal fixing plates, with claw facing down.
1. Pay attention to radial installation position of pressure regulators, see Figure 84.
NOTE: Torque limit 5.5N.

J. Install cable haness and connect pressure regulators(6x).
NOTE: Pay attention to installation position of cable hamess, see also markings(Figure
65).

K. Install female connector against shoulder, with groove facing guide nose of cover.
L. Install gaskets(Figure 86) and fasten cover using socket head screws.
NOTE: Torque limit 0.56 kg-m (4 ft lb).
(S) Box spanner(Torx TX-27)-5873 042 002

M. Install female connector using retaining clamp, see Figure 87.
N. Install opposite cover.

o. Install two adjusting screws and mount gasketl.
NOTE: Pay attention to different gaskets, see Figure 88 and Figure 91.
(S) Adjusting screws-5870 204063
O. Install two adjusting screws and mount gasketl.

9. Intermediate plate-version with screens: A. Insert screens (6x) flash -mounted into bore of intermediate plate, see Figure 89.
NOTE: Pay attention to installation position screens are facing up(facing duct plate).

9. Intermediate plate-version with screens: A. Insert screens (6x) flash -mounted into bore of intermediate plate, see Figure 89.
NOTE: Pay attention to instalation position screens are facing up(facing duct plate).

B. Mount intermediate plate, with screens with screens facing up.

C.Mount gasket ll.

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D. Mount duct plate and fasten it uniformly using socket head screws.
NOTE: Torque limit 1 kg-m(7ft lb).
(S) Box spanner(Torx TX-27)-5873 042 002

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E. install new O-rings on plugs(8x) and install them.
NOTE: Torque limit 0.61 kg-m
(4.4ftlb).
NOTE: The instalation of hydraulic control unit is described in following section,"Mount Duct Plate"on page 1-132.

Introduction of Doosan Excavator Transmission System(3)

 This article is about the detailed introduction of Doosan excavator transmission system (3)

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SPECIAL TOOLS
Engine Connection

HINO HIECHO-II (Hino EPC System) Heavy/Medium Duty EPC

Oil Pipes

 

HYDRAULIC CONTROL UNIT
(HSG-94)
Figure 62, shows a sectional view of HSG-94.
IMPORTANT Different versions in relation to position of cable harness are possible.
In this connection, pay attention to Specifications of Vehicle Manufacturer.
Transmission and Torque Converter

 

Transmission and Torque Converter Page 68
Disassembly
1. Figure 64, shows complete control unit.
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2. Mark installation position of different covers, housing and cable harness with valve housing.
26

3. Remove socket head screws.
4. Separate duct plate,1st gasket, intermediate plate and 2nd gasket from valve housing.

(S) Box spanner(Torx TX-27)-5873 042 0025. Remove retaining clip.Transmission and Torque Converter
6. Remove socket head screws.
7. Separate cover from housing and cable harness.
(S) Box spanner(Torx TX-27)-5873 04200210. Remove socket head screws, remove fixing plate and pressure regulators (3x).
(S) Box spanner(Torx TX-27)-5873 042 002

11. Remove two socket head screws and locate housing provisionally, using adjusting screws.(Housing is under spring preload). Remove remaining socket and screws.
(S) Box spanner(Torx TX-27)-5873 042 002
(S) Adjusting screws-5870 204036

12. Separate housing from valve housing by loosening adjusting screws uniformly.

13. Remove components(Figure 73).

14. Remove opposite pressure regulators, housing and components accordingly(Figure 74).