Doosan DL220 Power Steering System DISASSEMBLY

  This article introduces Doosan DL220 Power Steering System DISASSEMBLY

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  It is very important to keep the inside of the steering unit clean.

Make sure that the outside of the steering unit is clean before
opening the unit. Use a wire brush and solvent to clean the
entire unit.
1. Remove steering column from steering unit. Bolt steering
unit to stabilizing base. Bolt base to work bench.
2. Remove bolts from steering unit end cover. See Figure 30.

3. Remove end cover from unit. See Figure 31.

4. Lift cylinder gear off unit. See Figure 32. Remove two Orings.

5. Remove spacer bushing and spacer from cylinder gear (If
equipped). See Figure 33.
NOTE: Refer to parts manual for our unit to determine if
these parts are installed.

6. Remove shaft from housing. See Figure 34.

7. Remove distributor plate from housing. See Figure 35.

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8. Remove O-ring from top of middle plate. See Figure 36.

9. Lift middle plate off housing. See Figure 37.

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10. Remove O-ring from housing. See Figure 38.

11. Unscrew threaded bushing and remove it. See Figure 39.

12. Remove cross pin. See Figure 40

13. Shake ball out of housing. See Figure 41.

14. Pull sleeve and spool out of housing. See Figure 42.

15. Remove thrust bearing and thrust washers from sleeve.
See Figure 43. Remove spacer ring. Be sure to remove
spacer ring. It can stick in sleeve.

16. Carefully slide control spool out of sleeve. See Figure 44.

17. Push neutral position springs out of groove in spool. See
Figure 45.

18. Remove dust seal from housing. See Figure 46. Remove

O-ring and backup ring from inside housing.

19. Figure 47, shows all parts removed from steering unit.
Clean all parts before assembly. Use only new O-rings and

seals. 

Installation of Fuel Pump for Isuzu 4JJ1 Euro 4n Series Engine

This article mainly introduces the Installation the Isuzu engine oil pump

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Installation
1. Install the O-ring to the supply pump.
· Apply soapy water to the O-ring.
2. Install the supply pump.
a. Install the space rubber A (4) to the cylinder block.
b. Insert the space rubber B(2) into the supply pump bracket(3).
c. Install the supply pump bracket (3) in the following sequence.
1. Temporarily tighten the nuts and bolt on the gear case side until they are firmly attached to the gear case.
2. Temporarily tighten the bolts on the cylinder block side until they are firmly attached to the cylinder block.
3. Tighten the nuts and bolt on the gear case side to the specified torque.
Tightening torque:25 N,m(2.5kg-m/18 lbft)
4. Tighten the bolts on the cylinder block side to the specified torque.
Tightening torque:25 N.m(2.5kg-m/18 lb-ft) NOTE:
· Do not hold the high pressure pipe of the pump instead of the handle when installing the supply pump.
· Make sure the O-ring is not protruding.

b. Confirm that the supply pump gear and the main gear (3) of the idle gear A are engaged. Push in the supply pump gear with the supplypump gear engaged with the sub gear(4) of the idle gear A

5. Install the timing chain and the supply pump sprocket.
a. Align the alignment mark (1) of the idle gear D and the blue plate(2) of the timing chain.
b. Align the alignment mark (3) of the supplypump sprocket and the yellow plate(4) of the timing chain.
c. Align the dowel pin of the supply pump gearand the notch of the supply pump sprocket, and install the supply pump sprocket.
d. Tighten the supply pump shaft nut with your hand.

8. Install the timing chain tensioner (2), gasket(3).
and oll feed pipe (1) and tighten at the specified torque.
Timing chain tensioner Tightening torque:
10N-m(1.0kg-m/87 lb-ft)
Oil feed pipe Tightening torque:
15N.m(1.5kg-m/11 lbt)

9. Remove the hook of the tensioner.
· Lightly push the area indicated with an arrow in the diagram.
The hook of the tensioner is removed, the plunger pushes the tension lever, and the chain is pulled.

10 tghten the supply pump shaft nut(1) at the specified torque.
Tightening torque:130 N-m(13.3kgm/96 b-t)

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11. Tighten the timing chain lever pivot at the specified torque.
Tightening torque:27 N-m(2.8 kg-m/20 lb-t)
12. Turm the crankshaft pulley 720°(two revolutions)
to make the tension in the chain even.
13. Align the alignment mark(1) of the camshaft bearing cap and the camshaft.

14. Install the cylinder head cover.
Refer to "Cylinder Head Cover"in Section 1B, Engine Mechanical.
15. Apply liquid gasket(TB-1207C or equivalent) to upper timing chain cover(1).
· After applying the liquid gasket, install the cover within five minutes.

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Legend
1. Lower chain cover
2. Bolt
3. Nut
19. Connect the camshaft position sensor connector
(1) and the engine coolant temperature sensor connector(2).
· Fasten the engine coolant temperature sensor connector harness to the connector with a clip
(3).

LNWA18SH30400120. Connect the fuel temperature sensor harness connector(1) and suction control valve harness connector(2).

21. Install the common rail.
Refer to "Common Rail"in this Section,
22. Install the A/C compressor bracket, and tighten at the specified torque.
Tightening torque:25N-m (2.5kg-m/18 lb-ft)
23. Install the A/C compressor adjust pulley, and tighten at the specified torque.
Bolt tightening torque:25N.m(2.5kg-m/18 lb-ft) Nut tightening torque:25 N-m(2.5kg-m/18 Ib-ft)

24. Install the A/C compressor.
· Install the A/C compressor, and tighten at the specified torque.
Tghtening torque:25 N-m(2.5kg-m/18 Ib-ft)
· Install the drive belt and adjust its tension using the adjust bolt of the tension pulley.
· Refer to "Drive Belt"in Section 1C, Engine Cooling
25. Install the engine oil level gauge guide tube, and tighten it at the specified torque.
Tightening torque:25 N,m(2.5kg-m/18 lb-A)
26. Install the left side fan guide bracket.
Refer to "Water Pump"in Section 1C, Engine Cooling.
27. Install the engine cover.
Tghtening torque:25 N-m(2.5 kg-m/18 lb-t)
28. Install the left side noise cover.
29. Install the dropping register harness connector.
30. Install the air cleaner outlet duct.
31. Install the radiator upper hose.
· Tighten radiator hose clip.
Tightening torque:5 N-m(0.5kgm/43 lb-in)32. Install the air intake duct and hose.
NOTE: Firmly insert the hose without any twisting or misalignment, and tighten the clamp to the specified torque.

· Install the duct and hose between the intake throttle valve and intercooler.
· Use a new hose clamp, align it with the marking.
Tghtening torque:8 N.m(0.8 kg-m/69 lbin)

33. Connect the connector of the boost sensor.
34. Refl the coolant.
Supply Pump Relearn
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Command the Fuel Supply Pump Learn Reseting with the scan tool.
4. Observe the Fuel Supply Pump Status Parameter with the scan tool. Confirm the scan tool indicates Not Learned.
5. Start the engine and let idle until engine coolant temperature reads 20℃ (68F) or higher while observing the Fuel Supply Pump Status parameter with a scan tool. The scan tool parameter changes status Not Learned>Learned.

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Perkins 2806F Engine Fuel Manifold (ARD) Remove and Install

This paper mainly introduces how to Remove  and  Install Perkins 2806F Engine Fuel Manifold (ARD)

1. Turn the fuel supply to the OFF position.
2. Turn the battery disconnect switch to the OFF
position.

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3. Make temporary marks on harness assemblies (1).
Disconnect the harness assemblies from the
pressure sensors.
4. Cut cable straps (3) from the harness assemblies.
5. Disconnect harness assembly (2) and harness
assembly (4).
6. Disconnect the Original Equipment Manufacturer
(OEM) hose assembly (6). Remove O-ring seal (5)
(not shown)

7. Disconnect tube assembly (7) and tube assembly
(9).
8. Remove bolts (13) from Aftertreatment
Regeneration Device (ARD) fuel manifold (11) and
clip (12).
9. Remove ARD fuel manifold (11) from the bracket.
10. Remove O-ring seal (8) (not shown) and O-ring
seal (10) (not shown)

c. Remove adapter (23) from ARD fuel manifold
(11). Remove O-ring seal (22).
d. Remove adapter (20) and adapter (24) from
ARD fuel manifold (11). Remove O-ring seal
(21) and O-ring seal (25).
e. Remove nut (31) and washer (30).
f. Remove solenoid (29) from valve (28).
g. Use suitable tooling to remove valve (28) from
ARD fuel manifold (11).
h. Remove O-ring seal (26) and O-ring seal (27)
from valve (28).
i. Repeat Step 11.e through Step
11.h to remove
 the assembly of solenoid valve (19) from ARD
fuel manifold (11).
Installation Procedure
1. Ensure that all components of the ARD fuel
manifold are free from damage, wear, or
restriction.

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2. If necessary, follow Step 2.a through Step 2.h to
assemble ARD fuel manifold (11), install the
assembly of solenoid valve (18), and solenoid
valve (19).
a. Position ARD fuel manifold (11) in a suitable
support.
b. Install a new O-ring seal (21) and a new O-ring
seal (25) to adapter (20) and adapter (24).
Install the adapters to ARD fuel manifold (11).
Tighten the adapters to a torque of 17 N·m
(150 lb in)
c. Install a new O-ring seal (22) to adapter (23).
Install the adapter to ARD fuel manifold (11).
Tighten the adapter to a torque of 30 N·m
(266 lb in).
d. Install a new O-ring seal (26) and a new O-ring
seal (27) to valve (28) for the assembly of
solenoid valve (18).
e. Install valve (28) to ARD fuel manifold (11). Use
a deep socket to tighten the valve to a torque of
50 N·m (37 lb ft).
f. Install solenoid (29) to valve (28). Install washer
(30) and nut (31). Tighten the nut to a torque of
20 N·m (177 lb in).
g. Repeat Step 2.d through Step 2.f to install
remaining assembly of solenoid valve (19).
h. Install new O-ring seal (16) and new O-ring seal
(16) to pressure sensor (14) and pressure
sensor (15). Use a suitable deep socket to
install the pressure sensors to ARD fuel
manifold (11). Tighten the pressure sensors to a
torque of 28 N·m (248 lb in)

3. Install a new O-ring seal(8) (not shown) and a new
O-ring seal(10) (not shown) to the adapter on ARD
fuel manifold (11).
4. Install ARD fuel manifold (11) onto the bracket.
Install bolts (13) to clip (12) and the ARD fuel
manifold.
5. Connect tube assembly (7) and tube assembly (9)
to ARD fuel manifold (11). Tighten the tube nuts for
tube assemblies hand tight.
6. Tighten bolts (13) to a torque of 55 N·m (41 lb ft).
7. Tighten tube nuts for tube assembly (7) and tube
assembly (9) to a torque of 45 N·m (33 lb ft).
Ensure that the tube assemblies are not strained
as the tube nuts are tightened.

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8. Install a new O-ring seal (5) (not shown). Connect
the OEM hose assembly (6). Tighten the hose
assembly, refer to the OEM for the correct
tightening value.
9. Connect harness assembly (2) and harness
assembly (4). Install new cable straps (3) to the
harness assemblies.
Note: Ensure that the cable straps meet Original
Equipment Manufacturer (OEM) specifications.
10. Connect harness assemblies (1) to the pressure
sensors. Ensure that the harness assemblies are
connected in the original positions.
11. Turn the fuel supply to the ON position
12. Turn the battery disconnect switch to the ON
positio

Reinstallation of Doosan Pressure Control Sequence Valve

 This paper mainly introduces how to reinstall the doosan pressure control sequence valve

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1. Figure 16, shows PP plug and spool

2 Figure 17, shows outer spool and outer PP plug. Plug is
installed with spool.

3. Install spool into bore. See Figure 18. Use a nylon rod to
position spool in neutral position.

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4. Install spring and LS plug into bore. See Figure 19. Use a
new O-ring on plug

5. Use a 27 mm wrench to tighten PP plug and LS plug to 6
kg•m (44 ft lb). See Figure 20.

6. Assemble valve needle, spring and set screw into pressure
relief valve housing. See Figure 21. Thread pressure relief
valve into body of priority valve and tighten it. See Figure
21.





7. Install plug into pressure relief valve bore. Tighten plug to 5
kg•m (36 ft lb). See Figure 22.

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