How to Dismantle Doosan Excavator Pump

How to dismantle Doosan  DX 60-9C excavator pump

 Disassembly of the plunger pumps and the gear pumps

1. Remove the bolts (M1025L: 2), because the decomposition plunger pump and gear pump have O-ring on the joint surface, please be careful when separating.

· Tool: 8mm (factory —)

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 Figure  30

 2. Remove the coupling spline sleeve.

   

  Figure  31

 Disassemble the plunger pump

1. Remove the inner hexagon bolt (33,34) and separate the pump from the housing

End cover (21).

(M1230:3) (M1255:1)

· Tool: 10mm (factory —)

  

2. When removing the end cover, please separate in the horizontal direction. When the b is difficult to remove, please tap it gently with a plastic hammer.

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 3. Status after the pump end cover is removed.

 

 

 

4. Remove the O-ring (3 0,3 1).

 

 

 

5. Remove the adjustment spring.

 

    6. Remove the spring seat from the pump housing (51).

 

       

7. Remove the plunger plug assembly.

 

 

         

8. Use the hook to remove the slide track plate.

 

 

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9. Remove the clamp spring with the clamp (7).

  

   10. Remove the front cover (8).

 

 

       11. Remove the O-ring.

 

 

      14. Remove the bearing pads (14).

 

 

    15. Remove the bearing.

 

 

       

16. Remove the inclined plate.

 

 

    17. Remove the flow distribution plate.

 

 18. Remove the card spring (28).

 

 

         

19. Remove the filter screen (26).

 

 

 

  

20 Remove the retaining bolt (67) for the flow adjustment valve block (M8 x

25L: 2s)

If the bolt is coated with Loctite before assembly, please do not remove the cover bolt if not necessary.

· Tool: 6mm (factory 1)

 

 

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21. Separate and adjust the valve body. Because the binding surface has an O-ring, please be careful.

 

 22. Remove the flow adjustment valve spool.

 

 

    23. Remove the 3 disc springs and spring seats.

 

  

24. Remove the inner hexagon bolts and separate the cover bolts

(M830L: 2s)

· Tool: 6mm (factory —)

 

   

  26. Remove the overflow valve. Remove the inner hexagon bolts.

Note: Disassemble this part only if required.

· Tool: 24 mm (2e)

 

 

  

27. Remove the adjustment bolts

 Note: Due to the valve core.

 

 

   28. Separation spring.

 

 

    

29. Remove the spool.

 30. Disassembly of the drive shaft

 Remove the clamp spring and the bearing

 

 

 

      31. It may be difficult to remove the bearings and can be struck with a plastic hammer.

 

 

 

 

How to Inspect the Caterpillar Excavator Air Intake and Exhaust System

How to inspect the caterpillar325c excavator air intake and exhaust system 

 1. Inspection of air intake and exhaust systems 

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 (1) Inspection of air intake resistance. If there is resistance in the intake and exhaust systems, it will be the 1U-5470 engine pressure assembly (Figure 3-1-46). 

 1) Check the intake pipe and exhaust pipe of the engine air filter to ensure that the pipes are not leaking.

 2) Check the engine air filter element. Use a clean engine air filter

 3) Check whether there are traces of dirt on the clean side of the engine air filter element. If traces of dirt are observed, it means that the contaminants have entered the engine air filter element and/or filter element seal. . NOTE: Hot engine parts can cause burns. Allow the engine and parts to cool before servicing the engine. Contact with a running engine can result in burns from hot parts or damage from rotating parts. When working on a running engine, avoid contact with hot or rotating parts. 

 4) Measure using the differential pressure gauge in the 1U-5470 engine pressure test assembly  

①As shown in Figure 3-1-50, connect the vacuum port of the differential pressure gauge to test position 3. Test location 3 may be anywhere on intake manifold 2 behind engine air filter 4 and in front of wheel booster 1. 

 

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 ②Open the pressure port of the differential pressure gauge to allow it to communicate with the atmosphere. 

 ③Start the engine. Run the engine at high idle speed with no load. 

 ④Record the pressure value, multiply this pressure value by 1.8, and then compare it with the corresponding value below. There is resistance to airflow through an old engine air filter. There will also be some resistance to airflow through a clogged engine air filter. in In the above two cases, the resistance must not exceed 6.2kPa; the resistance of the air flowing through the new air filter element must not exceed 3.7kPa. 

 (2) Inspection of exhaust resistance. Back pressure is the pressure difference between the exhaust pressure at the elbow outlet and the atmospheric pressure. The tools required to check exhaust resistance are 1U-5470 engine pressure components (Figure 3-1-46). NOTE: Hot engine parts can cause burns. Allow the engine and components to cool before servicing the engine. Contact with a running engine can result in burns from hot parts or injury from rotating parts. When working on a running engine, avoid contact with hot or rotating parts. Use the differential pressure gauge in the 1U-5470 Engine Pressure Test Assembly to measure exhaust backpressure. Use the following steps to measure exhaust back pressure. 

 1) As shown in Figure 3-1-51, connect the vacuum port of the differential pressure gauge to test position

 

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    2. Test location 2 may be anywhere on exhaust pipe

 3 behind turbocharger 4 and in front of muffler 

1. 2) Open the pressure port of the differential pressure gauge to allow it to communicate with the atmosphere.  

3) Start the engine. Run the engine at high idle speed with no load. 

 4) Record the pressure value. 

 5) Multiply the value in step 4) by 1.80. 

 6) Compare the value in step 5) with the value below. The exhaust back pressure must not be greater than 10.OkPa.

How to Test a Caterpillar Excavator Unit Injector

 How to test a caterpillar 325C excavator unit injector  

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This step can help determine why the injector is misfiring. 

 

 (1) If you have not yet checked for the presence of air in the fuel, perform the inspection steps and 

 

refer to the "Air in Fuel Test" section. CAUTION: ELECTRIC SHOCK HAZARD. The voltage used 

 

by the electronic unit injector system is 90~120V.  

 

(2) Remove the valve cover and check if there are any broken parts. Repair or replace any broken parts 

 

found. Check all wiring to the solenoid coil. Check to see if the connectors are loose. Also check to see 

 

if the wiring is worn or disconnected. Make sure the connector on the unit injector solenoid coil is well 

 

connected. Perform a tensile test on each wire.

 

  (3) Check for signs of oil leakage. Investigate the cause of the fuel leak. Repair oil leaks.  

 

(4) For the single-piece injector cylinder that is suspected to be faulty, check the adjustment of the valve

 

 clearance. Please refer to the "Inspection and Adjustment of Engine Valve Clearance" section. 

 

 (5) Make sure the bolts holding the unit injector are tightened to the correct torque. To check the 

 

torque, loosen the bolts holding the unit injector. Tighten the bolts to the correct torque. 

 

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 (6) Remove the suspected faulty unit injector and check for signs of coolant leakage. Leaking coolant 

 

can cause corrosion on the fuel injectors. If the unit injector shows signs of leaking coolant, remove the 

 

injector sleeve and inspect it. If the injector sleeve is damaged, replace it. Inspect unit injectors for 

 

excessive brown stains that have spread to the injector tips. If excessive stains are found, check the fuel 

 

quality. Refer to the "Testing of Fuel Quality" section. Replace the seal on the injector and reinstall the 

 

injector. Check for soot accumulation on the surface of the injector seat. If soot accumulates, there is a 

 

gas leak. The cause of the leak should be found and repaired. If the fault is a gas leak, there is no need 

 

to replace the injector. 

 

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 (7) If the fault cannot be solved, replace the faulty injector with a new one.

 

How to Test the Fuel System Pressure of Caterpillar Excavator

  How to test the fuel system pressure of the caterpillar 325C excavator 

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 The tools required to test the fuel system pressure are 1U-5470 engine pressure test assembly, 3Y-2888 

connector and 3J-1970 O-ring seal. NOTE: Both the 5P-2720 Detector Engagement Set and the 

5P-2718 Pressure Detector can be used with these tools. These additional tools will be used later when 

installing the pressure probe. Fuel leaks or splashes on hot surfaces or electrical components can cause 

a fire. Spills should be removed immediately. Keep all parts clean and free of contamination.

  Contaminants can accelerate component wear and shorten their service life. Always be careful not to 

lose fluid when inspecting, maintaining, testing, adjusting, and repairing this equipment. Suitable 

containers should be prepared to collect the liquid before opening any box or disassembling any parts 

containing liquid. All liquids should be handled in compliance with local regulations. The 1U-5470 

engine pressure test assembly is shown in Figure 3-1-46. The 1U-5470 engine pressure test assembly 

can be used to check the engine’s fuel pressure. There is a gauge in the tool set that records the 

 pressure 

in the fuel manifold. The fuel return pipe is shown in Figure 3-1-47,

 and the fuel pressure test is shown in Figure 3-1-48.

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Whether under normal working conditions or under loaded working conditions, the fuel pressure should

 be within the range of 400~525kPa; during low idle speed operation, the fuel pressure at the fuel filter 

inlet should be within the range of 400~435kPa. If the pressure difference △P on both sides of the 

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is ignored, the fuel pressure in fuel supply channel 1 should be equal. For a new fuel filter, the pressure 

differential loss on both sides of it is usually 35kPa. If worn particles accumulate in the fuel filter, the 

pressure difference across it will increase. If the filter becomes clogged, the fuel supply pressure may 

drop to 69kPa before the driver notices significant power loss. If the fuel pressure is lower than normal, 

it will cause cavitation and cause internal damage to the unit injector. The pressure difference on both 

sides of the fuel filter should not exceed 69kPa. Pressure regulator 3 is mounted directly on the 

cylinder 

head. The pressure regulator is located at the fuel return port toward the rear end of fuel supply passage 

1. The oil hole maintains the fuel pressure at low engine speeds.

When checking the fuel pressure on the unfiltered side, follow these steps: 

 (1) Remove the plug from 

 

the fuel pressure gauge port 6. 

 (2) Install the joints, seals and 1U-5470 engine pressure test assembly to

 

the fuel pressure gauge interface 6, so that the pressure of the fuel transfer pump can be measured.

 

  When checking the fuel pressure in fuel supply passage 1, follow the steps below. 

 1) Remove the plug

 

 from fuel pressure gauge port 7. 

 

 2) Install the joints, seals and 1U-5470 engine pressure test assembly

 

 to the fuel pressure gauge interface 7. 3) Run the engine. 

 NOTE: Before checking fuel pressure, make 

 

sure the fuel filter is clean. A clogged fuel filter will cause the pressure at port 7 of the fuel pressure 

 

gauge to be lower than the pressure at port 6 of the fuel pressure gauge.

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