How to Reassemble Doosan DX520LC and DX480LC Hydraulic Excavator Stroke Motor Speed Reducer
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1. Install seal to jig. Figure 92.
2. Install jig to housing. Figure 93.
3. Clean seal surface. Figure 94.
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4. Install seal to hub using jig used in Step 1. Figure 95.
5. Apply lubricant to seal surface. Figure 96.
6. Support ball bearing housing with spacers (1 and 2, Figure 97) and install bearing into housing. Install spacer between balls,noting diameter shown in illustration.
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7. Install upper balls and upper housing. Figure 98.
8. Itall hub to housing. Figure 99.
9. Press hub into housing using a press and a stopper. Figure 100.
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10. Install four bushings using a press. Figure 101.
11. Assemble planetary gear assembly. Figure 102.
12. Install four planetary gear assemblies, using press. Figure 103.
13. Tighten gear box of planetary gear assembly to 150 Nm (110.7 ft lb). Figure 104.
14. Assemble third shift sun gear. Figure 105.
15. Assemble the second shift reduction assembly. Figure 106.
16. Place planetary gear carrier on hub. Figure 107.
17. Press planetary gear carrier into hub. Figure 108.
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18. Apply loctite to planetary gear carrier fastening bolts. 19. Install and tighten bolts. Figure 109.
NOTE: In next step, the O-ring and backup rings are
different. Be careful not to switch them.
20. Install O-ring to end cover. Figure 110.
21. Install end cover to housing.
NOTE: Apply Loctite 243 to bolts and torque to 10 Nm
(7.38 ft lb). Figure 111
22. Tighten plugs to 6 - 8 Nm (4.42 - 5.90 ft lb). Figure 112.
23. Turn housing over and install second shift sun gear. Figure 113.
24. Install first shift planetary gear assembly. Figure 114.
25 Install first shift sun gear. Figure 115
26. Install O-ring (1, Figure 116) and backup ring (2) into hub groove.
NOTE: The O-ring and backup rings are different. Be
careful not to switch them.
27 Install brake shaft while turning the reduction gear assembly. Figure 117.
28. Install brake disc assembly, starting with a copper disc (seven pieces) and alternating with steel discs (six pieces). Figure 118 and Figure 119.
29. Install jig to hub and insert spring retainer disc under left side of retaining ring. Figure 120.
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30. Install retaining ring using retaining ring pliers. Figure 121.
31. Install O-ring to hub groove. Figure 122.
32. Place brake piston inside hub being careful not to damage seal. Figure 123.
33. Insert springs into brake piston holes. Figure 124.
34. Install retainer disc. Figure 125.
