2022年7月13日星期三

Doosan Steering Pressure Control Sequence Valve Setting

This article introduces the pressure control sequence valve setting of Doosan steering gear

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Theory of Operation Oil output from the steering pump flows through the priority valve to both the loader supply line and to the steering circuit. During operation of the steering wheel, the priority valve shifts and supplies pump flow only to the steering circuit. This results in smooth operation of the steering circuit.
At rest, the spool(1, Figure 4) maintains an open path between inlet port P and steering outlet port CF. Port EF is kept closed by the force from spring (2, Figure 4). The spool(1, Figure 4)
contains a drilled passage. The passage is open to port CF and is also open to both ends of the spool. At the neutral position of the steering unit, oil from port P flows through port CF and into the drilled passage in the spool. At this time, oil flowing out of CF is blocked at the control spool of the steering unit. This raises the pressure in port CF. At this time, port LS is open to the chamber on the far right side of the priority valve. Port LS is notopen to the chamber on the far left side of the valve. As oil flows through the drilled passage in the spool, pressure builds on the left side of the spool but pressure is low on the right side of the spool because oil can drain into port LS. When oil pressure on the left side of the spool rises above the force of spring (2, Figure 4), the spool(1, Figure 4) shifts the right. This allows pump flow at port P to flow out both ports CF and EF. Now both the loader supply line and the steering supply line are charged with flow from the steering pump. Whenever the steering wheel is turned, the spool in the steering unit directs some oil flow back to port LS. This equalizes the oil pressure on both ends of thespool(1, Figure 4). The spring now shifts the spool to the left.
This closes off the passage from port P to port EF. This makes all steering pump flow now available only to the steering circuit from port CF.

SPECIAL TOOLS
1. The following tools are necessary to repair the priority valve. See Figure 6.
Open end wrench-27mm Slip joint pliers Nylon rod Allen wrenches-5 mm,8 mm and 10mm

DISASSEMBLY
1.Use open end wrench to loosen PP plug.See Remove O-ring.

2.Use open end wrench to loosen LS plug.See Figure 8.
Remove O-ring.

3.Remove spring.See Figure 9.

4.Use a nylon rod to push spool out of bore.See Figure 10.

5.Use an 8 mm allen wrench to remove plug from pressure relief valve.See Figure 11

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6.Use a 10 mm allen wrench to unscrew pressure relief valve from its bore.See Figure

7.Hold pressure relief valve with a pliers and use a 5 mm allen wrench to remove set screw.See Figure 13.

8. The pressure relief valve is composed of a valve housing, valve needle, spring and set screw. See Figure 14.

CLEANING AND INSPECTION
(WEAR LIMITS AND TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures"section.
Clean all parts with a nonflammable, nontoxic solvent.
Carefully inspect all parts. Replace all worn or broken parts. Use only new O-rings to assemble the valve.
Cost all parts with oil before assembling them.

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2022年7月12日星期二

Perkins EngineFuel Filter Base - Install

This article describes the installation of the Perkins 2806F engine fuel filter base

Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the fuel filter base and bracket are free
from wear or damage. Replace any component
that is worn or damaged.
Illustration 14 g06079253
2. If necessary, follow Step 2.a through Step 2.h to
assemble and install bracket (12).
a. If necessary, follow Step 2.a through Step 2.d to
assemble bracket (12).
b. Install mount (19), mount (21), and limiter (18)
to bracket (12). Ensure that the mounts are
correctly orientated.
c. Install bolt (16) and washer (17). Ensure that the
washer is correctly orientated.
d. Install washer (20) and nut (22). Tighten the nut
and bolt (16) to a torque of 25 N·m (221 lb in).
e. Install washer (23) to bolt (16)

f. Repeat Step 2.b through Step 2.e to install
remaining washer (23), nut (22), washer (20),
bolt (16), mount (19), mount (21), and limiter
(18) from bracket (12).
g. Position bracket (12) onto the cylinder block.
Install bolt (14) and bolt (15).
Tighten bolt (14) to a torque of 214 N·m
(158 lb ft).
Tighten bolt (15) to a torque of 47 N·m
(35 lb ft).
h. Install bolt (13) to the tube assembly clip.
Tighten the bolt to a torque of 47 N·m (35 lb ft)
3. Install fuel filter base (3) to the bracket. Install nuts
(2) and tighten to a torque of 25 N·m (221 lb in).
4. Position bracket (7) onto fuel filter base (3). Install
nuts (8). Tighten the nuts to a torque of 25 N·m
(221 lb in).
5. Remove the plug from tube assembly and the cap
from connection on the fuel filter base. Install a
new O-ring seal (5) (not shown). Ensure that the
O-ring seal is correctly installed into the recess of
the adap6. Connect tube assembly (6) to fuel filter base (3).
Install nut (11) for clip on tube assembly. Tighten
the tube nut for the tube assembly to a torque of
60 N·m (44 lb ft).
Tighten the nuts to a torque of 25 N·m (221 lb in).
7. Remove the plug from the hose assembly and the
cap from connection on the fuel filter base.
Connect hose assembly (10) to fuel filter base (3).
Tighten the hose assembly to a torque of 60 N·m
(44 lb ft).
8. Connect the harness assembly to fuel temperature
sensor (1).
9. Connect the harness assembly to fuel pressure
sensor (4).
10. Install new fuel filters (9). Refer to Operation and
Maintenance Manual, “Fuel Filter - Replace” for
the correct procedure.
11. Turn the fuel supply to the ON position.
12. Remove the air from the fuel system. Refer to
Systems Operation, Testing and Adjusting, “Fuel
System - Prime” for the correct procedure.

2022年7月10日星期日

Fuel Priming Pump - Remove

This article is about how to disassemble the fuel filter base

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Removal Procedure
1. Turn the fuel supply to the OFF position.
2. Turn the battery disconnect switch to the OFF
position.
3. For the correct location of the fuel priming pump
assembly. Refer to Original Equipment
Manufacturer (OEM) for the correct location.

4. Remove fuel filter (9). Refer to Operation and
Maintenance Manual, Fuel System Primary Filter
(Water Separator) Element - Replace for the
correct procedure.
5. Disconnect harness assembly (2), harness
assembly (3), and harness assembly (8).

6 M0070446
Disassembly and Assembly Section

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9. If necessary, follow Step 9.a through Step 9.j to
disassemble the assembly of fuel filter base (1).
a. Place the assembly of fuel filter base (1) in a
suitable support.
b. Remove nut (21) and remove solenoid (22).
c. Use a deep socket to remove valve (23).
Remove O-ring seal (24), O-ring seal (25), and
backing ring (26).
d. Remove check valve (35). Remove O-ring seal
(30), O-ring seal (29), and backing ring (28)
e. Remove bolts (27) from manifold (34). Remove
O-ring seal (33).
f. Remove O-ring seal (19) and backing ring (20).
g. Make temporary marks on wiring harness (37)
for installation purposes. Remove locking nuts
(32). Remove electronic filter (31) and
disconnect the wiring harness from pump
assembly (43).
h. Remove pump assembly (43) from fuel filter
base (1). Remove backing ring (40), seal (41),
backing ring (42), and seal (39).
i. If necessary, remove circlip (36) and remove
wiring harness (37) from fuel filter base (1).
6 M0070446
Disassembly and Assembly Section
Remove O-ring seals (38).
j. If necessary, remove plug (48) from fuel filter
base (1). Remove O-ring seal (47). Remove
spring (46), valve (45), and O-ring seal (44).
If necessary, repeat Step 9.j to remove
remaining valve assembly (49).
Installation Procedure
1. Ensure all the components of the fuel priming
pump assembly are free from wear, damage, and
restriction.
Illustration 5 g06096521
M0070446

Correct orientation of fuel priming pump (44).
Correct position of electronic filter (32)
Position (A) is the negative (-) terminal on fuel priming
pump (44)
Position (B) is the positive (+) terminal on fuel priming
pump (44)
2. If necessary, follow Step 2.a through Step 2.m to
assemble the assembly of fuel filter base (1).
Note: Use the pump seal installer that is provided
in the pump kit to press in the new pump and the
seals.
a. Place the assembly of fuel filter base (1) in a
suitable support.
b. If necessary, install new O-ring seals (38) to
wiring harness (37). Install the wiring harness to
fuel filter base (1). Ensure that the wiring
harness is correctly installed into the fuel filter
base. Install circlip (36) to the fuel filter base.
Ensure that the circlip is correctly installed into
the recess of the fuel filter base.
c. Install new seal (39), backing ring (42), seal
(41), backing ring (40) to pump assembly (43).
d. Install pump assembly (43) to fuel filter base (1).
Ensure that the pump assembly is installed
into the fuel filter base squarely, is correctly
seated, and is correctly orientated into the
fuel filter base. Refer to Illustration 7 for the
correct orientation.
e. Connect wiring harness (37) to pump assembly
(43). Ensure that the harness assembly is
correctly connected to the pump assembly.
Refer to Illustration 7 .
f. Install electronic filter (31) to pump assembly
(43). Refer to Illustration 7 . Install new locking
nuts (32). Tighten the locking nuts to a torque of
1.3 N·m (1 lb ft)
g. Install new O-ring seal (19) and backing ring
(20) to pump assembly (43). Ensure that the Oring seal and the backing ring are correctly
installed.
h. Install a new O-ring seal (33) to fuel filter base
(1). Install manifold (34). Install bolts (27).
Tighten the bolts to a torque of 12 N·m
(106 lb in).
i. Install new O-ring seal (24), O-ring seal (25),
and backing ring (26) to valve (23). Ensure that
the O-ring seal and the backing ring are
correctly positioned.
j. Use a deep socket to install valve (23). Tighten
the valve to a torque of 50 N·m (37 lb ft).
k. Install solenoid (22) to valve (23). Install nut
(21). Tighten the torque to 6.5 N·m (58 lb in)
l. Install new O-ring seal (30), O-ring seal (29),
and backing ring (28) to check valve (35). Install
the check valve to manifold (35). Tighten the
check valve to a torque of 34 N·m (301 lb in).
m. If necessary, install a new O-ring seal (47) to
plug (48). Install a new O-ring seal (44) onto
valve (45). Install the valve, spring (46), and the
plug to fuel filter base (1). Tighten the plug to a
torque of 90 N·m (66 lb ft).
If necessary, repeat Step 2.m to install
remaining valve assembly (50).

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3. If necessary, follow Step 3.a through Step 3.c to
install mounts (13), mounts (10), limiters (16),
limiter (11), and bracket (14) to fuel filter base (1).
a. Install mount (10), limiter (11) and mount (12) to
fuel priming pump (1).
b. Install limiters (16) and mounts (17) and mounts
(15) to fuel priming pump (1).
c. Install bracket (14) and mounts (13).
4. Position fuel priming pump base (1) onto the OEM
mounting point. Install bolts (6) and washers (5) to
the fuel priming pump base. Tighten the bolts to a
torque of 27 N·m (239 lb in).
5. Connect harness assembly (2), harness assembly
(3), and harness assembly (8).
6. Install a new fuel filter (9). Refer to Operation and
Maintenance Manual, Fuel System Primary Filter
(Water Separator) Element - Replace for the
correct procedure.
7. Turn the fuel supply to the ON position.
8. Turn the battery disconnect switch to the ON
position.
9. Remove plug and cap from the connections and
the hose assemblies. Connect the OEM hose
assemblies to the connections (4) Tighten the
hose assemblies, refer to the OEM for the correct
torque value.
10. Remove cap from connection (4a) and connect
the OEM hose assemble. Tighten the hose
assemblies, refer to the OEM for the correct torque
value.
11. Follow Step 11.a through Step 11.c to flush the
fuel pump and the hose assembly for the supplies
to the Aftertreatment Regeneration Device (ARD).
M0070446 9
Disassembly and Assembly Section
a. Disconnect the hose assembly from the ARD.
Use two people to flush the fuel pump and the
hose assembly for the supplies to the ARD into
a suitable container for disposal.
b. The fuel pump can be activated by turning on
the key or pressing the manual switch. The
manual switch, if available, the switch is on the
primary fuel filter base.
c. After the flushing procedure has been carried
out, connect the hose assembly to the ARD.
Tighten the hose assemblies, refer to the OEM
for the correct torque value.

2022年7月7日星期四

install the output flange of doosan transmission system

This article introduces how to install the output flange of doosan transmission system

1.Assemblea sheet and press both inner bearing race against shoulder until contact is obtained.

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2. Insert outer bearing race(Figure 254) into the housing bore until contact is obtained.

3. Position screening plate.

4. Insert output shaft.

5. Fasten both sheets using socket head screws (4x).
NOTE: Insert socket head screws with Loctite (Type
No. 243).
NOTE: Torque limit (M8/8.8) 2.35 kg•m (17 ft lb)

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6. Squeeze rectangular rings (6x) into the recesses of the
clutch shafts and hook them in.
7. Grease rectangular rings and align them centrically

8. Insert both O-rings (Figure 259) into the annular groove of
the oil pipes and grease them.

9. Cover mounting face with sealing compound Loctite #574.
10. Install adjusting screws (S) and position housing cover
carefully against gearbox housing until contact is obtained,
using lifting device.
NOTE: Pay attention to the overlapping of the oil pipe
with the bores in the housing cover.
(S) Adjusting screws - 5870 204 007

11. Install both cylindrical pins
(S) Lifting chain - 5870 281 047

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12. Fasten housing cover using hex. head screws.
NOTE: Torque limit (M10/8.8) 4.69 kg•m (34 ft lb).
NOTE: Pay attention to the position of the fixing plate,
see Figure 262.

13. Install shaft seal, with the sealing lip facing the oil chamber.
NOTE: By application of the prescribed driver, the exact
installation position is obtained. Wet rubber
coated outer diameter with spirit. Grease
sealing lip.
(S) Driver - 5870 048 057

14. Heat the output flange (Max. 90°C (194°F)), assemble it
and attach it using washer and hex. head screws.
NOTE: Wet contact area of washer with sealing
compound Loctite (Type No. 574).
NOTE: Torque limit (M8/10.9) 3.47 kg•m (25 ft lb).

15. Assemble both axial washers and needle cage.
NOTE: Upper and lower axial washer have the same
thickness (50x 70x 1).

16. Assemble both needle bearings

17. Assemble idler gear.

18. Assemble axial washer (3, Figure 229) (50 x 70 x 1) needle
cage (2) and running disk (1) (50 x 70 x 4).
NOTE: Install running disk 1 with the chamfer facing the
needle cag

19. Assemble pre-assembled plate carrier until all inner plates
are accommodated

20. Attach plate carrier axially using retaining ring.
(S) Set of external pliers - 5870 900 015
(S) Handle - 5870 260 010

21. Press tapered roller bearing against shoulder.
22. Install opposite tapered roller bearing
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23,Check function of the clutch using compressed air.
NOTE: With correctly installed components, the
closing, reap. opening of the clutch is clearly
audible.

2022年7月5日星期二

Install Preassembled Output Shaft and Clutches

This article is an introduction to installing a preassembled output shaft and

The clutch

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NOTE: The following Figures describe the common
installation of all clutches. For it, the housing cover,
combined with special tool (Handle 5870 260 010) is
needed. The reassembly of single clutches without
housing cover and handles is extremely difficult
because of the installation conditions. Besides, there
is the danger of injury.
1. Insert all outer bearing races into the housing cover until
contact is obtained.
NOTE: In the case that already run bearings are
reused, pay attention to the allocation of the
outer bearing races, see also Note,

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2. Insert clutch KR, input shaft and clutch KV together into
housing
02

3. Install clutch K4.
03

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4. Install clutch K3

04

5. Position clutch K1.

6. Insert clutch K2.

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7. Figure 246, shows the installation position of the single
clutches in the housing cover.

8. Locate all clutches using Handles (S).
(S) Handle (6 pieces needed) - 5870 260 010
08

9. Squeeze rectangular rings (7 pieces, see Figure 248) in
and hook them in.

10. Grease rectangular rings and align them centrically
11. Tilt housing cover 180°.
12. Mount eye bolts, see Figure 249.
(S) 2x Eye bolt M20 - 0636 804 003
(S) lx Eye bolt M16 - 0636 804 001
(S) Puller device - 5870 000 017

10

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13. Install adjusting screws (S).
14. Position housing cover using lifting device carefully on the
gearbox housing until contact is obtained, reap. position
the clutches in the gearbox housing.
NOTE: Pay attention to the overlapping of the oil pipes
with the bores in the housing cover.
(S) Lifting chain - 5870 281 047
(S) Adjusting screws - 5870 204 007