Doosan dl450 3 wheeled loader service repair manual

Page 1

Fig. 011 CYLINDER HEAD

DL450-3

Fig. 011 CYLINDER HEAD Key No

Part No

Description

Qty S.C

1

150113-00262

HEAD,CYLINDER

6

2

110949-00315

SLEEVE

1

3

430221-00581

PLUG,CORE

2

4

120407-00033

RIVET

2

5

110922-00468

GUIDE,VALVE

4

6

401107-01143

SEAL,VALVE

2

6

401107-01144

SEAL,VALVE

2

7

401107-01145

SEAL,VALVE

2

7

401107-01146

SEAL,VALVE

2

8

120501-02048

PIN

12

9

120501-02043

PIN

12

10

400602-00473

GASKET

6

11

401107-01142

SEAL,VALVE;STEM

24

12

410112-00047

VALVE,INTAKE

12

13

111601-00429

SPRING,VALVE;INTAKE

12

14

110917-00291

COLLAR,SPRING;VALVE

12

15

410112-00046

VALVE,EXHAUST

12

16

111601-00431

SPRING,VALVE;EX(OUTER)

12

17

111601-00430

SPRING,VALVE;EX(INNER)

12

18

110917-00292

COLLAR,SPRING;VALVE

12

19

410201-00032

COTTER,VALVE;COLLET

48

20

160606-00005

BRIDGE;VALVE

12

21

120705-00708

SCREW

36

22

110411-00137

BRACKET ASSY

6

23

430221-00592

PLUG;RIVET

6

24

120705-00710

SCREW

6

25

150101-00040

ARM,ROCKER;INTAKE

6

26

120702-00031

SCREW,ADJUSTING

1

27

120307-00114

NUT,HEX

1

28

-

BUSH

1

29

430221-00593

PLUG;RIVET

2

30

401003-00354

RING;RETAINING

6

31

150101-00039

ARM,ROCKER;EXHAUST

6

32

120702-00031

SCREW,ADJUSTING

1

33

120307-00114

NUT,HEX

1

34

-

BUSH

1

DL450-3

1

OS

OS

D

D

Serial No

ICA

Replacable

Qty

Key No

Part No

Description

Qty S.C

35

430221-00593

PLUG;RIVET

2

36

401003-00355

RING;RETAINING

6

DL450-3

2

Serial No

ICA

Replacable

Qty

Fig. 012 ROCKER COVER

DL450-3

Fig. 012 ROCKER COVER Key No

Part No

Description

Qty S.C

1

110508-08926

COVER;ROCKER

6

2

110508-08927

COVER;ROCKER

3

3

110508-08929

COVER;ROCKER

2

4

110508-08928

COVER;ROCKER

1

5

110508-08922

COVER

1

6

400602-00476

GASKET;ROCKER COVER

6

7

120705-00748

SCREW;FLANGE

18

8

400602-00477

GASKET;ROCKER COVER

6

9

120705-00732

SCREW;FLANGE

24

DL450-3

1

L1

Serial No

ICA

Replacable

Qty

Fig. 013 CYLINDER BLOCK

DL450-3

Fig. 013 CYLINDER BLOCK Key No

Part No

Description

Qty S.C

1

150102-00398

BLOCK,CYLINDER

1

2

-

CAP

6

D

3

-

CAP

1

D

4

110949-00316

SLEEVE,GUIDE

14

5

120705-00713

SCREW

14

6

131002-00381

BUSHING,BEARING

7

7

430221-00582

PLUG,CORE

2

8

430221-00583

PLUG,CORE

5

9

150117-00026

LINER,CYLINDER

6

10

401003-00356

RING

6

11

401002-00701

RING,O

6

12

401002-00699

RING,O

6

13

140111-00016

METAL,MAIN;CRANK

7

13

140111-00017

METAL,MAIN;CRANK(0.25)

7

US

13

140111-00018

METAL,MAIN;CRANK(0.5)

7

US

15

120816-00097

WASHER,THRUST;CRANK

4

15

120816-00099

WASHER,THRUST(0.16)

4

OS

15

120816-00100

WASHER,THRUST(0.26)

4

OS

16

430218-00157

NOZZLE;PISTON COOLING

6

17

120705-00685

SCREW,BANJO CONNECTOR

1

18

110508-08924

COVER;CHAMBER

3

19

400602-00455

GASKET

3

20

120705-00747

SCREW;FLANGE

18

21

-

FLANGE

1

22

400602-00467

GASKET

1

23

120705-00735

SCREW;FLANGE

4

24

110508-08917

COVER

1

25

400602-00475

GASKET

1

26

120705-00731

SCREW;FLANGE

9

27

120705-00754

SCREW;FLANGE

2

28

110949-00319

SLEEVE,SPACER

2

29

110411-00138

BRACKET;LIFTING

1

30

120705-00703

SCREW

3

31

110949-00324

SLEEVE,SPACER

3

32

430221-00586

PLUG,SCREW

1

33

120808-00541

WASHER,SEAL

1

DL450-3

1

D

Serial No

ICA

Replacable

Qty

Key No

Part No

Description

Qty S.C

34

430208-00232

CONNECTER;HOSE

1

35

430221-00586

PLUG,SCREW

1

36

120808-00541

WASHER,SEAL

1

DL450-3

2

Serial No

ICA

Replacable

Qty

Fig. 014 TIMING GEAR COVER

DL450-3

Fig. 014 TIMING GEAR COVER Key No

Part No

Description

Qty S.C

1

110508-08925

COVER;FRONT

1

2

401107-01135

SEAL

1

3

120501-02046

PIN

2

4

910101-00014

SILICONE

1

5

120705-00732

SCREW;FLANGE

8

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 015 FLYWHEEL HOUSING

DL450-3

Fig. 015 FLYWHEEL HOUSING Key No

Part No

Description

Qty S.C

1

150114-00145

HOUSING,FLYWHEEL

1

2

110508-08909

COVER

2

3

401107-01137

SEAL

1

4

120705-00756

SCREW,HEX

9

5

120808-00533

WASHER

9

6

120705-00742

SCREW;FLANGE

11

7

120705-00743

SCREW;FLANGE

1

8

120705-00739

SCREW;FLANGE

5

9

120705-00740

SCREW;FLANGE

1

10

110508-08918

COVER

1

11

401002-00696

RING,O

1

12

120705-00739

SCREW;FLANGE

2

13

110508-08906

COVER

1

14

110508-08913

COVER

1

15

120705-00730

SCREW;FLANGE

4

16

250201-01691

PLATE;TIMING GEAR

1

17

120501-02046

PIN

2

18

120705-00746

SCREW;FLANGE

6

19

430221-00573

PLUG

1

20

120705-00730

SCREW;FLANGE

1

21

120808-00537

WASHER

1

22

110411-00115

BRACKET;LIFTING

2

23

120408-00079

STUD

12

24

120305-00030

NUT,FLANGE

12

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 016 BREATHER SYSTEM

DL450-3

Fig. 016 BREATHER SYSTEM Key No

Part No

Description

Qty S.C

1

420108-00572

HOSE

1

2

120202-00144

CLAMP,HOSE

3

3

420210-00858

PIPE

1

4

110411-00119

BRACKET

1

5

120705-00730

SCREW;FLANGE

3

6

401002-00697

RING,O

1

7

240302-00003

SEPARATOR,MIST

1

7A

101529-00226

KIT,REPAIR;SEPARATOR

1

8

120705-00749

SCREW;FLANGE

4

9

400602-00463

GASKET

1

10

420210-00862

PIPE

1

10A

420108-00573

HOSE

1

11

120705-00729

SCREW;FLANGE

2

12

120202-00145

CLAMP,HOSE

1

17

420210-00861

PIPE

1

18

420210-00865

PIPE,DRAIN

1

19

401002-00698

RING,O

1

20

120203-00288

CLAMP

2

21

120705-00730

SCREW;FLANGE

2

22

110411-00131

BRACKET

1

23

120705-00738

SCREW;FLANGE

3

24

110411-00130

BRACKET

1

25

120705-00745

SCREW;FLANGE

1

26

120705-00686

SCREW;FLANGE

1

27

120808-00535

WASHER

2

28

500203-00047

CLEANER;OIL

1

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 017 OIL PAN

DL450-3

Fig. 017 OIL PAN Key No

Part No

Description

Qty S.C

1

150119-00269

SUMP,OIL

1

2

430221-00594

PLUG;INSERT

1

3

400604-00014

GASKET,OIL PAN

1

4

120705-00754

SCREW;FLANGE

18

5

430221-00576

PLUG

1

6

401002-00686

RING,O

1

7

120705-00725

SCREW;FLANGE

2

8

430221-00585

PLUG,MAGNETIC

1

9

120808-00545

WASHER,SEAL

1

10

160633-00031

FRAME,LADDER

1

11

400602-00472

GASKET

1

12

120705-00750

SCREW;FLANGE

36

13

120705-00753

SCREW;FLANGE

6

DL450-3

1

L1

Serial No

ICA

Replacable

Qty

Fig. 018 CRANK MECHANISM

DL450-3

Fig. 018 CRANK MECHANISM Key No

Part No

Description

Qty S.C

1

150121-00172

ROD ASSY,CONNECTING

6

2

120705-00704

SCREW

2

4

140111-00013

METAL,CONNECTING ROD

12

4

140111-00014

METAL,CONNECTING ROD(0.25)

12

US

4

140111-00015

METAL,CONNECTING ROD(0.5)

12

US

5

150107-00394

CRANKSHAFT

1

6

180313-00157

DAMPER;TORTION

1

7

130418-00362

GEAR;CRANK SHAFT

1

8

120501-02045

PIN

1

9

150111-00139

FLYWHEEL

1

10

130422-00050

GEAR,RING

1

11

120705-00712

SCREW

10

12

120408-00082

STUD

8

13

120311-00110

NUT,LOCK

8

14

120808-00536

WASHER

8

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 019 PISTON

DL450-3

Fig. 019 PISTON Key No

Part No

Description

Qty S.C

-

130602-00781

PISTON ASSY

6

2

401003-00357

RING,COMPRESSOR

1

3

401003-00358

RING,COMPRESSOR

1

4

401003-00360

RING,SCRAPER;OIL

1

5

111104-00236

RING,RETAINING

2

6

120501-02051

PIN;GUDGEON

1

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 020 CAM SHAFT DRIVE

DL450-3

Fig. 020 CAM SHAFT DRIVE Key No

Part No

Description

Qty S.C

1

150103-00060

CAMSHAFT

1

2

120501-02044

PIN 10x25

1

3

130712-00770

SHAFT ASSY

3

4

130112-00052

TAPPET;ROLLER

4

5

110949-00323

SLEEVE,SPACER

2

6

111104-00239

RING,RETAINING

4

7

110949-00317

SLEEVE,GUIDE

2

8

120705-00747

SCREW;FLANGE

6

9

120705-00707

SCREW

3

10

150123-00083

PUSHROD

12

12

130408-00013

GEAR,CAMSHAFT

1

13

120705-00755

SCREW,HEX

5

14

430215-00521

FLANGE,GUIDE

1

15

120816-00098

WASHER,THRUST;CAM SHAFT

1

16

120705-00746

SCREW;FLANGE

2

17

130418-00362

GEAR;CRANK SHAFT

1

18

130418-00365

GEAR ASSY;INTERMEDIATE

1

19

130418-00360

GEAR

1

20

130712-00768

SHAFT

1

21

140105-00303

BEARING

1

22

111104-00240

RING,SNAP

1

23

110949-00325

SLEEVE,SPACER

1

24

120705-00700

SCREW

1

26

130418-00364

GEAR;INTERMEDIATE

1

27

130712-00768

SHAFT

1

28

140105-00303

BEARING

1

29

111104-00240

RING,SNAP

1

30

110949-00325

SLEEVE,SPACER

1

31

120705-00700

SCREW

1

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 021 OIL FILLER

DL450-3

Fig. 021 OIL FILLER Key No

Part No

Description

Qty S.C

1

430215-00519

FLANGE

1

2

400602-00456

GASKET

2

3

120705-00731

SCREW;FLANGE

4

4

120202-00144

CLAMP,HOSE

2

5

420108-00577

HOSE

1

6

420210-00855

PIPE

1

7

110910-00451

CAP

1

7A

400602-00460

GASKET

1

8

110928-00174

HOLDER

1

9

110411-00136

BRACKET

1

10

120705-00724

SCREW;FLANGE

2

11

800108-00089

GAUGE,LEVEL

1

12

420210-00863

PIPE

1

13

430208-00219

CONNECTER

1

14

120808-00540

WASHER,SEAL

1

15

120305-00028

NUT,FLANGE

1

16

120705-00695

SCREW

1

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 022 TURBO CHARGER PLUMBING

DL450-3

Fig. 022 TURBO CHARGER PLUMBING Key No

Part No

Description

Qty S.C

1

420210-00852

PIPE;LUBRICATION

1

6

430208-00227

CONNECTER

1

7

400602-00452

GASKET

1

8

420210-00867

PIPE;RETURN

1

9

400602-00470

GASKET

1

10

120705-00730

SCREW;FLANGE

1

11

420108-00571

HOSE

1

12

120202-00147

CLAMP,HOSE

2

13

120203-00291

CLAMP

1

14

120705-00687

SCREW

2

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 023 OIL FILTER

DL450-3

Fig. 023 OIL FILTER Key No

Part No

Description

Qty S.C

1

400405-00088

FILTER ASSY,OIL

1

2

430208-00227

CONNECTER

1

3

120808-00540

WASHER,SEAL

1

4

401002-00700

RING,O

1

5

401002-00693

RING,O

1

6

401002-00692

RING,O

1

7

400504-00058

ELEMENT,OIL FILTER

1

8

101529-00223

KIT,REPAIR

1

9

101529-00225

KIT,REPAIR;BY-PASS V/V

1

11

400602-00469

GASKET

1

12

120705-00732

SCREW;FLANGE

7

13

120705-00736

SCREW;FLANGE

2

14

120705-00737

SCREW;FLANGE

1

15

500203-00047

CLEANER;OIL

1

16

130712-00769

SHAFT

1

17

120808-00538

WASHER

1

18

120705-00719

SCREW,PLUG

1

19

430221-00579

PLUG

1

20

130602-00780

PISTON

1

21

111601-00428

SPRING

1

22

400602-00450

GASKET

1

23

210206-00090

ROTOR ASSY

1

24

-

BEARING

1

D

25

-

BEARING

1

D

26

-

NOZZLE

2

D

27

110508-08910

COVER

1

28

401002-00703

RING,O

1

29

120312-00345

NUT

1

30

400411-00039

STRAINER

1

31

110508-08908

COVER

1

32

120311-00108

NUT,LOCK

1

33

120808-00534

WASHER

1

34

401002-00690

RING,O

1

35

111104-00241

RING,SNAP

1

36

401002-00702

RING,O

1

37

400602-00471

GASKET

1

DL450-3

1

L1

L1

Serial No

ICA

Replacable

Qty

Key No 38

Part No 120705-00737

DL450-3

Description

Qty S.C

SCREW;FLANGE

4

2

Serial No

ICA

Replacable

Qty

Fig. 024 OIL COOLER

DL450-3

Fig. 024 OIL COOLER Key No

Part No

Description

Qty S.C

Serial No

1

110508-08923

COVER ASSY

1

2

110508-08907

COVER

1

3

400602-00451

GASKET

1

4

120705-00724

SCREW;FLANGE

5

5

430208-00227

CONNECTER

1

6

120808-00540

WASHER,SEAL

1

7

430201-00587

ADAPTER

1

8

120808-00542

WASHER,SEAL

1

9

110949-00318

SLEEVE;PROTECTION

1

10

430221-00572

PLUG

2

11

120501-02047

PIN

1

12

130602-00780

PISTON

1

13

111601-00427

SPRING

1

14

400602-00450

GASKET

1

15

430221-00587

PLUG,SCREW

1

16

400206-00344

COOLER,OIL

1

~6521913

16

400206-00361

COOLER,OIL

1

6521914~

17

400602-00453

GASKET

2

18

400602-00454

GASKET

2

19

120705-00732

SCREW;FLANGE

4

~6521913

19

120705-00894

SCREW;FLANGE

4

6521914~

20

120501-02050

PIN,DOWEL

2

21

400602-00474

GASKET

1

22

120705-00753

SCREW;FLANGE

11

23

120705-00750

SCREW;FLANGE

1

24

110949-00319

SLEEVE,SPACER

1

25

430221-00580

PLUG

1

26

401002-00695

RING,O

1

27

120705-00730

SCREW;FLANGE

1

28

430221-00578

PLUG

2

29

401002-00691

RING,O

2

DL450-3

1

ICA

Replacable

Qty

Fig. 025 OIL PUMP

DL450-3

Fig. 025 OIL PUMP Key No

Part No

Description

Qty S.C

1

400915-00150

PUMP,OIL

1

2

120705-00733

SCREW;FLANGE

6

3

110949-00317

SLEEVE,GUIDE

4

4

120705-00750

SCREW;FLANGE

4

5

420210-00868

PIPE;SUCTION

1

6

120705-00731

SCREW;FLANGE

3

7

420210-00864

PIPE

1

8

401002-00686

RING,O

2

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 026 EXHAUST MANIFOLD

DL450-3

Fig. 026 EXHAUST MANIFOLD Key No

Part No

Description

Qty S.C

1

240102-00167

MANIFOLD,EXHAUST

1

2

240102-00166

MANIFOLD,EXHAUST

1

3

401109-00077

SEALRING

2

4

240102-00165

MANIFOLD,EXHAUST

1

3

401109-00077

SEALRING

2

5

400602-00458

GASKET

6

6

120705-00751

SCREW;FLANGE

12

7

110949-00320

SLEEVE,SPACER

1

8

400602-00468

GASKET

1

9

120705-00752

SCREW;FLANGE

2

10

110949-00322

SLEEVE,SPACER

2

11

120408-00081

STUD

2

12

120305-00032

NUT,FLANGE

2

13

150105-00320

CHARGER,TURBO

1

DL450-3

1

L1

Serial No

ICA

Replacable

Qty

Fig. 027 TURBO CHARGER PLUMBING

DL450-3

Fig. 027 TURBO CHARGER PLUMBING Key No

Part No

Description

Qty S.C

1

410135-00286

VALVE,SOLENOID

1

2

120705-00702

SCREW

2

3

110411-00126

BRACKET

1

4

420108-00575

HOSE

1

5

120202-00143

CLAMP,HOSE

4

6

430201-00586

ADAPTER ASS'Y

1

7

120705-00727

SCREW;FLANGE

2

8

110411-00125

BRACKET

1

9

120705-00730

SCREW;FLANGE

7

10

120203-00288

CLAMP

5

11

420108-00575

HOSE

1

12

110411-00120

BRACKET

1

13

120705-00730

SCREW;FLANGE

2

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 028 INTAKE MANIFOLD

DL450-3

Fig. 028 INTAKE MANIFOLD Key No

Part No

Description

Qty S.C

1

240203-00105

MANIFOLD,INTAKE

1

2

400602-00457

GASKET

6

3

120705-00737

SCREW;FLANGE

24

4

401109-00076

SEALRING

1

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 029 POWER TAKE OFF(1)

DL450-3

Fig. 029 POWER TAKE OFF(1) Key No

Part No

Description

Qty S.C

1

401002-00696

RING,O

1

2

130418-00361

GEAR

1

3

111104-00238

RING,RETAINING

1

4

140107-00300

BEARING,ROLLER

1

5

111104-00237

RING,RETAINING

1

6

110931-00712

HOUSING

1

7

120705-00739

SCREW;FLANGE

5

8

401002-00688

RING,O

1

9

110508-08919

COVER

1

10

401002-00689

RING,O

1

11

120705-00744

SCREW;FLANGE

2

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 030 POWER TAKE OFF(2)

DL450-3

Fig. 030 POWER TAKE OFF(2) Key No

Part No

Description

Qty S.C

1

110508-08912

COVER

1

2

120408-00083

STUD

3

3

120305-00030

NUT,FLANGE

3

4

110949-00321

SLEEVE,SPACER

3

5

401002-00708

RING,O

1

6

401002-00707

RING,O

1

DL450-3

1

Serial No

ICA

Replacable

Qty

Fig. 031 CHARGE AIR PIPE

DL450-3

Fig. 031 CHARGE AIR PIPE Key No

Part No

Description

Qty S.C

1

420202-00228

PIPE,AIR;CHARGE

1

2

120203-00294

CLAMP

1

3

401002-00694

RING,O

1

4

420202-00229

PIPE,AIR;CHARGE

1

7

401109-00076

SEALRING

1

8

120705-00689

SCREW

2

9

120705-00687

SCREW

2

DL450-3

1

Serial No

ICA

Replacable

Qty

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