Doosan — Crank Case Ventilation System Reroute - Air Filter and Hoses

Repair & overhaul · Air filter base, intake elbows, CCV hoses

From a Doosan service manual covering: PSI HD 14.6L, PSI HD 18.3L, PSI HD 21.9L. Check it applies to your exact model before use.

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Procedure

1. Loosen the clamp holding both CCV hose to the master and slave bank intake elbows.
2. MASTER (RIGHT) BANK ONLY: Remove four 10mm bolts securing air filter to mixer. Rotate air filter assembly 90° counter clockwise. Reinstall four bolts.
3. Remove the plugs from both master and slave air filter bases. Set these aside, they will be needed again. 3/8" Allen key will be needed.
4. Remove the straight fittings from both master and slave intake elbows. 7/8" socket will be needed.
5. Install brass plugs from air filter base into intake elbows. DO NOT OVER TORQUE THIS PLUG; ELBOW DAMAGE CAN OCCUR.
6. Install straight fittings into air filter base. DO NOT OVER TORQUE THIS PLUG; FITTING DAMAGE CAN OCCUR.
7. MASTER (RIGHT) BANK ONLY: Remove FOUR inches of hose and insulation from the master bank.
8. SLAVE (LEFT) BANK ONLY: Remove TWO inches of hose and insulation from the master bank.
9. Verify a droop is not present in the CCV hose.
10. Install CCV hoses onto straight fitting in air filter base. Tighten clamp and install new zip tie to secure insulation.
11. Remove four bolts on top of Racor canister. Remove CCV hoses on T. Verify Racor filter integrity; if oil saturation present, replace.
12. Before installing the cap and filter, verify the o-ring is present around the cap!
13. Reinstall the cap and the four bolts. Install the CCV hoses on the T and tighten the hose clamps.
14. Visually inspect the catalyst substrates for oil saturation. The picture shown is a clean catalyst for reference.
15. Verify the oil level is correct. Top off as needed.

Source: Doosan service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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