Doosan DX480LC - SINGLE GEAR PUMP

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SP000033Gear Pump

Page 6

SINGLE GEAR PUMP

Disassembly

1. Clean exterior of pump.

2. Remove clamp bolts.

3. Cover sharp edges of drive shaft with adhesive tape and

coat shaft end extension with clean grease, to avoid any

damage to lip of shaft seal when removing mounting

flange.

FG001072

Figure 1

FG001074

Figure 2

FG001073

Figure 3

Table of Contents

Table of Contents11
- Track Excavator Safety13
- Safety Precautions13
- Applicable Models13
- To the Operator of a DOOSAN Excavator14
- General Safety Essentials17
- Location of Safety Labels18
- Summary of Safety Precautions for Lifting in Digging Mode18
- Unauthorized Modifications19
- General Hazard Information19
- Before Starting Engine28
- Machine Operation32
- Maintenance39
- Battery47
- Towing49
- Shipping and Transportation50
- Lifting with Sling50
Table of Contents55
- Applicable Models57
- Safety Precautions57
- General Description59
- Component Locations60
- General Dimensions62
- Working Range64
- General Specifications66
- Engine Performance Curves (Per DIN 6270 Standard)68
- Approximate Weight of Workload Materials70
- Performance Tests72
- Excavator Performance Standards73
- Test Conditions73
- Travel Speed and Travel Motor Balance (Steering Deviation) Tests73
- Swing Speed and Deceleration Force Test75
- Cylinder Performance Tests77
Table of Contents83
- Applicable Models85
- Safety Precautions85
- Welding Precautions and Guidelines86
- Hydraulic System - General Precautions87
- General Precautions89
- Maintenance Service and Repair Procedure89
- Hydraulic System Cleanliness and Oil Leaks90
- Maintenance Precautions for Hydraulic System Service1090
- Oil Leakage Precautions91
- Cleaning and Inspection92
- General Guidelines92
- Bearing Inspection93
Table of Contents103
- Applicable Models105
- Safety Precautions105
- Torque Values for Standard Metric Fasteners106
- Torque Values for Standard U.S. Fasteners107
- Type 8 Phosphate Coated Hardware109
- Torque Values for Hose Clamps110
- Torque Values for Split Flanges111
- Torque Multiplication112
- Torque Wrench Extension Tools112
- Other Uses for Torque Wrench Extension Tools113
- Tightening Torque Specifications (Metric)114
Table of Contents121
- Applicable Models123
- Cabin123
- Safety Precautions123
- Removal124
- Installation128
Table of Contents133
- Applicable Models135
- Safety Precautions135
- General136
- Warning for Counterweight and Front Attachment Removal6136
- Removal138
- Installation139
Table of Contents143
- Applicable Models145
- Safety Precautions145
- General Description146
- Parts List146
- Specifications147
- Removal148
- Installation152
- Start-Up Procedures155
Table of Contents159
- Applicable Models161
- Safety Precautions161
- General Description162
- Theory of Operation162
- Replacement of Rotor and Vane163
- Troubleshooting163
- Replacement of Armature164
- Replacement of Rear Cover164
Table of Contents167
- Applicable Models169
- Safety Precautions169
- Measuring Bearing Lateral Play170
- Measuring Swing Bearing Axial Play170
- Operating Recommendation170
- Swing Bearing Maintenance170
- Disassembly171
- Swing Bearing Basic Operation171
- Assembly173
Table of Contents177
- Applicable Models179
- Safety Precautions179
- General Description181
- Theory of Operation181
- Parts List182
- Specifications183
- Troubleshooting, Testing and Adjustment184
- Removal185
- Disassembly186
- Cleaning and Inspection (Wear Limits and Tolerances)195
- Assembly of Carrier Subassemblies196
- Reassembly196
- Shaft and S/R Bearing Heat-Fit196
- Assembly of Main Case202
- Assembly of Motor218
- Installation222
- Start-Up Procedures223
Table of Contents229
- Applicable Models231
- Safety Precautions231
- General Description232
- Track Tension233
- Cleaning and Inspection235
- Track Shoe236
- Lower Roller238
- Upper Roller239
- Front Idler240
- Track Removal241
- Track Shoes and Links241
- Track Installation242
- Front Idler Roller244
- Parts List244
- Front Idler Roller Disassembly245
- Front Idler Roller Reassembly247
- Lower Roller248
- Parts List248
- Lower Roller Disassembly249
- Lower Roller Removal249
- Lower Roller Reassembly250
- Lower Roller Installation251
- Parts List252
- Upper Roller252
- Upper Roller Disassembly253
- Upper Roller Removal253
- Upper Roller Reassembly255
- Parts List256
- Track Spring and Track Adjusting Cylinder256
Table of Contents261
- Applicable Models263
- Safety Precautions263
- Drive Coupling264
- Special Tools265
- Drive Coupling Installation266
- Installation Procedure268
Hydraulic System Troubleshooting, Testing and Adjustment/Hydraulic System Troubleshooting, Testing and Adjustment273
- Hydraulic System Troubleshooting, Testing and Adjustment274
- Applicable Models275
- Safety Precautions275
- General Notes276
- Hydraulic System - General Notes276
- Boom down Circuit279
- Boom Operating Circuit279
- Boom up Circuit279
- Operation of Working Components279
- Arm Crowd Circuit280
- Arm Dump Circuit280
- Arm Operating Circuit280
- Bucket Crowd Circuit281
- Bucket Dump Circuit281
- Bucket Operating Circuit281
- Swing Operating Circuit281
- Left Swing Operating Circuit282
- Right Swing Operating Circuit282
- Swing Relief Valve and Makeup Valve282
- Travel Operating Circuit282
- Forward Travel Circuit283
- Reverse Travel Circuit283
- Initial Checks and Tests to Establish Operating Condition of the Excavator284
- Procedural Troubleshooting Baseline Recommendations284
- Adjustment and Testing286
- Pilot Pressure286
- Current Signal and Hydraulic Pressure Adjustments287
- Power Mode Valve287
- Checks and Adjustments288
- Pressure up Valve288
- Pump Input Power Control290
- Pump Regulator Adjustment290
- Flow Meter and Flow Meter Kit Installation and Testing293
- Precautions/Initial Checks295
- Swing System Troubleshooting295
- Swing Relief Valve Checking and Adjustment296
- Troubleshooting - Swing Gearbox298
- Troubleshooting - Hydraulic Problems299
- Troubleshooting - Control Valve301
- Troubleshooting - Travel Control Valve302
- Troubleshooting - Joystick Control Valve303
Table of Contents307
- Applicable Models309
- Safety Precautions309
- General Description310
- Specifications312
Table of Contents315
- Applicable Models317
- Safety Precautions317
- General Description318
- Parts List319
- Inspection320
- Testing320
- Troubleshooting, Testing and Adjustment320
- Disassembly321
- Reassembly324
Table of Contents329
- Applicable Models331
- Safety Precautions331
- General Description332
- Theory of Operation332
- Parts List334
- Piston Nut336
- Special Tools and Materials336
- Piston Jig338
- Steel Bushing Jig340
- Dust Wiper Jig342
- Slipper Seal Jig344
- Slipper Seal Straightening Jig346
- Disassembly348
- Reassembly353
Table of Contents359
- Applicable Models361
- Safety Precautions361
- General Description362
- Theory of Operation362
- Makeup Check Valve365
- Operation of Swing Reactionless Valve365
- Operation of Time Delay Valve365
- Parts List366
- Specifications368
- Torques368
- Tools369
- Tools and Materials369
- General Precautions370
- How to Check Faults of Hydraulic Motor370
- Troubleshooting370
- Troubleshooting, Testing and Adjustment370
- Disassembly372
- General Cautions372
- Cleaning and Inspection (Wear Limits and Tolerances)379
- Assembly380
- General Cautions380
- Reassembly380
- Assembly of Cylinder Block Assembly Subassembly383
- Assembly of Rear Cover Assembly Subassembly387
- Air Pressure Test393
- Oil Leakage Check393
Table of Contents397
- Applicable Models399
- Safety Precautions399
- General Description401
- Structure401
- Operation Basics402
- Parts List408
- Connection Torque410
- Specifications410
- General Precautions412
- How to Check Faults of Hydraulic Motor412
- Troubleshooting412
- Troubleshooting, Testing and Adjustment412
- Disassembly414
- General Cautions414
- Disassembly of Cylinder Subassembly420
- Cleaning and Inspection422
- Maintenance Standard422
- Tolerances)422
- General Cautions426
- Reassembly426
- Reassembly of Drive Shaft Subassembly426
- Assembly of Valve Casing Subassembly427
- Assembly of Cylinder Subassembly431
- Assembly of Motor Body433
Table of Contents441
- Applicable Models443
- Safety Precautions443
- Axial Piston Pump444
- General Description444
- Model Number Designation444
- Theory of Operation445
- Parts List446
- Torques448
- Tools449
- Troubleshooting, Testing and Adjustment451
- Disassembly453
- Cleaning and Inspection (Wear Limits and Tolerances)456
- Worn Part Replacement Criteria456
- Correction Criteria for Cylinder, Valve Plate and457
- Plate (Shoe Plate)457
- Reassembly458
- Cautions During Starting Operation462
- Oil Filling and Air Venting462
- Start-Up Procedures462
- General Description463
- Model Number Designation463
- Regulator for Axial Piston Pump463
- Parts List464
- Outline465
- Functional Explanations467
- Specifications467
Table of Contents487
- Applicable Models489
- Gear Pump489
- Safety Precautions489
- Disassembly490
- Single Gear Pump490
- Reassembly492
- Disassembly496
- Double Gear Pump496
- Reassembly498
Table of Contents505
- Parts List540
- Specifications545
- Troubleshooting546
- Troubleshooting, Testing and Adjustment546
- Adjustment of Valves547
- Disassembly549
- Cleaning559
- Cleaning and Inspection (Wear Limits and Tolerances)559
- Inspection559
- Caution on Assembly560
- Reassembly560
- Sequence of Subassembly561
- Maintenance of Relief Valves567
- Installation570
- Start-Up Procedures570
Table of Contents573
- Applicable Models575
- Safety Precautions575
- General Description577
- Theory of Operation577
- Parts List578
- Specifications580
- Tools and Materials580
- Torques580
- Disassembly581
- Cleaning and Inspection585
- Reassembly585
- Tolerances)585
- Start-Up Procedures592
Table of Contents621
- Applicable Models623
- Safety Precautions623
- 5-Solenoid Valve624
- Parts List624
- Functions of 5-Solenoid Valve Assembly625
- Assembly Diagram and Tools Required628
- Cautions During Disassembly and Reassembly629
- Solenoid Valve Diagram630
- Check Points and Solutions for Problems631
- 2-Solenoid Valve632
- Parts List632
- Assembly Diagram and Tools Required633
- Cautions During Disassembly and Reassembly634
- Solenoid Valve Diagram635
Table of Contents639
- Applicable Models641
- Breaker EPPR Valve (Opt)641
- Safety Precautions641
- Numbers and Names of Parts642
- Structure642
- Cautions for Operation643
- Functions and Operation643
- Maintenance644
- Maintenance Instructions644
- Disassembly645
- Assembly646
Table of Contents661
- Applicable Models664
- Safety Precautions664
- Introduction665
- Electrical Supply System666
- Engine Starting Circuit668
- Engine Preheating System672
- Engine Stop674
- Charging System676
- Monitoring System677
- Operation682
- Warning and Indicator Lights684
- Initial Operation687
- Mode Selector Switch687
- Graphic Information Area Display688
- Main Menu690
- Special Menu695
- Electronic Hydraulic Control System (E-EPOS)712
- Power Mode Control714
- Power Mode Control - Circuit Diagram719
- Engine Control System720
- Engine Control Motor721
- Engine Control Dial722
- Engine Control Circuit Diagram723
- Automatic Deceleration Control (Auto Idle Control)724
- Engine Overheat Protection System726
- Power Boost Mode728
- Automatic Travel Speed Control730
- Self-Diagnostic Function733
- Air Conditioner System735
- Troubleshooting755
- Weight of R134A Gas Used in Machines757
- Refrigerant System Repairs758
- Wiper System766
- Lighting System768
- Overload Warning Device770
- Audio Controller771
Table of Contents785
- Applicable Models787
- Boom and Arm787
- Safety Precautions787
- Front Attachment Pin Specifications788
- Dx300Lc789
- Dx340Lc / Dx350Lc790
- Dx420Lc791
- Dx480Lc / Dx520Lc792
- Arm Removal Procedure793
- Front Attachment - Removal and Installation793
- Boom Removal Procedure795
- Arm Installation Procedure796
- Boom Installation Procedure796
- Installation796
- Start-Up Procedures797
- Applicable Models803
- Bucket803
- Safety Precautions803
- Bucket Tooth Inspection and Replacement804
- Bucket O-Ring Replacement805
- Bucket Shimming Procedures807
- New Bucket Installation807
- Attaching the Bucket809
- Bucket Attachment, Removal and Reversal809
- Detaching the Bucket809
- Reversing the Bucket810

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