Doosan D110S-5 with OCDB Disassembly/Assembly
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Doosan D110S-5 with OCDB Disassembly/Assembly

Vehicle system
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See also: Operating Manual
Vehicle System
Disassembly & Assembly
D110S-5
with OCDB
D130S-5
with OCDB
D160S-5
with OCDB
SB4376E01
A u g . 2 0 1 2

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Summary of Contents for Doosan D110S-5 with OCDB

  • Page 1 SB4376E01 A u g . 2 0 1 2 Vehicle System Disassembly & Assembly D110S-5 with OCDB D130S-5 with OCDB D160S-5 with OCDB...
  • Page 3 If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

  • Page 5: Table Of Contents

    INDEX Universal Joint ........50 Forks ............5 Removal & Installation ........50 Remove & Install Forks ........5 Disassembly & Assembly .........51 Carriage ........... 6 Steering Wheel & Gear ......52 Remove & Install Carriage ......... 6 Steering Wheel ..........52 Carriage Rollers ........7 Removed &...

  • Page 7: Forks

    Forks Remove & Install Forks 3. Support the fork with strap and hoist. Remove shaft (4). Remove strap and hoist from the fork. The weight of the fork is 217 to 465 kg (477 to 1025 lb). 4. Tilt the mast at full forward direction. Lower the 1.

  • Page 8: Carriage

    Carriage NOTE : The following steps are for installation of the carriage. See the topic entitled Carriage Adjustment in the Testing and Adjusting Manual before installing Remove & Install Carriage the carriage on the mast. Start By : a. Remove forks. 1.

  • Page 9: Carriage Rollers

    Carriage Rollers Remove & Install Carriage Rollers Start By : a. Remove carriage. 1. Remove snap ring (1) from the roller. 1. Remove the snap ring (1) that holds the roller in place. 2. Remove load roller (2) from the carriage. NOTE : The following steps are for installation of the 2.

  • Page 10: Disassemble & Assemble Carriage

    5. Install snap ring (1) in the roller. 3. Remove bolts (4), washers, roller and bracket assembly (3) and shims (5) from carriage End By : assembly. a. Install carriage rollers (load) Disassemble & Assemble Carriage Start By : a. Remove carriage Tools Needed 4.

  • Page 11: Mast

    Mast Remove Mast Start By : a. Remove carriage. 1. Fully lower mast. 4. Bend back the tab on clip (4). 5. Remove bolt (3), clip (4) and block (2). 2. Fasten a hoist to the mast as shown. WARNING Tilt cylinders can drop when pin (6) is removed.

  • Page 12: Install Mast

    Install Mast 6. Connect hydranlic lines (1). NOTE : If lift cylinders were removed from the mast, 1. Install the mast on the frame of the vehicle. The adjust both lift chains to equal tension. Run the mast weight of the mast is approximately 2600 to 4400 to full lift.

  • Page 13: Std Mast

    STD Mast Disassembly Start By : a. Remove mast. 5. Remove bolt (12) and washers. 1. Remove hose (1) and bracket (2). 2. Remove hose (3), flow protector (4) and flow regulating and bracket assembly (5) from outer mast channel. 6.
  • Page 14 12. Remove snap-ring (19) from the inner mast pin. Remove roller assemblies (20) from the inner mast channel. NOTE : Place identification marks on all roller assemblies (20) to assure proper installation. 9. Remove pads (15) and shims from the outer mast channel.
  • Page 15 17. Remove snap-ring (24), bearing (25) from roller 20. Support crosshead assembly (32) with a hoist (26) if needed. and remove eight bolts, washers (31) and crosshead assembly (32) from the inner mast channel. 18. Remove bolt (27), washer and grease fitting. Tap the shaft and remove shaft (28), spacers (30), 21.

  • Page 16: Assembly

    Assembly Tools Needed Vernier Calipers Inside Vernier Calipers Mast Gauge 1. Make sure all parts are clean and free of dirt and foreign material. 2. Check all parts for damage. If damaged, use new parts for replacement. 5. Put crosshead assembly (32) in position and install washers and bolts (31).
  • Page 17 8. Install the shaft, spacers and roller (29) to the bracket. 10. Install the inner mast channel side roller and Install bolt (27) and washer using Loctite No.242. bracket assemblies (22) without shims on the Install grease fitting (28) to the shaft. Be careful inner mast.
  • Page 18 NOTE : Assemble after spray to anti-seizing 19. Place the shims between wear pads (15) and the lubricant, Molybdenum disulfide type between inner mast. Clearance (X) between outer roller bearing and roller. (16) and inner mast flange is to be 0.0 to 1.0 mm 16.
  • Page 19 24. Install clamp assembly (10), pad-rubber (9), spacers (8), plate (7) and nut (6). Bend plate (7) supporting nut (6) not to be loosened. NOTICE Make lift cylinders vertical by adjusting pad-rubber (9) and U-clamp assembly (10). 25. Install grease pipe if it was removed. 26.

  • Page 20: Fft Mast

    FFT Mast Shaft Tilt Cover NOTE: Since many things for FFT are same for STD, please also refer to the instruction for STD. 1. Remove the mast chassis a) Remove tilt pin from the (1) & tilt cylinder Chain anchor b) Remove hinge pin (2) c) Remove mast from chassis 2.
  • Page 21 clamp 3. Remove hydraulic line. a) Remove attachment line(1) - Remove bolt & fitting - Close the port with plug b) Remove lift line(2) Bolt(pin) - Remove clamp & fitting 5. Remove cylinder - Close the port with plug a) Remove primary cylinder - Remove clamp(1) - Remove cylinder fitting bolt b) Remove secondary cylinder(2)

  • Page 22: Lift Cylinder

    Lift Cylinder 6. Remove bearing & mast as a) Remove side roller bearing (1) Removal & Installation b) Remove mast roller bearing (2) 1. Start the engine and lift the inner mast. Put blocks under the inner mast as shown and lower the End by: weight on the blocks.
  • Page 23 5. Move the lift control lever to the "DOWN" position NOTE : The following steps are for the installation of and push rod (2) into the cylinder to get enough the lift cylinder. clearance for removal. 9. Fasten a hoist to the lift cylinder and put it in 6.

  • Page 24: Disassembly

    Disassembly Start By : a. Remove lift cylinder. 11. Make sure the bolt holes in the end of rod (2) are in alignment with the bolt holes in the inner mast plate. Start the engine. Move rod (2) out of the cylinder until it is in correct alignment with the inner mast plate.
  • Page 25 3. Remove rod (3) from the cylinder body. 6. Remove wiper seal (8) and U-packing (9) from the head assembly. 7. Inspect bushing (10) in the head assembly. If the bushing has a large amount of wear, make a replacement of the bushing and head as a unit. The parts can not be ordered separately.

  • Page 26: Assembly

    Assembly 4. Install O-ring seal (7) onto the head assembly. 1. Install dust wiper seal (11) in the head. 5. Install wear rings (6), back-up ring (5) and U- 2. Install bushing (10) and U-packing (9). packing (4) on the piston. NOTE : U-packing (9) should be installed with the lip of the seal toward the outside of the head.

  • Page 27: Tilt Cylinder

    Tilt Cylinder Removal & Installation 7. Install head assembly (2) on the cylinder rod and tighten it using tool. End By : a. Install lift cylinders. 1. Start the engine. Tilt the mast forward until rod end pin (2) can be removed. Stop the engine. WARNING If both tilt cylinders are to be removed, fasten a hoist to the mast and put a support in position...

  • Page 28: Disassembly & Assembly

    Disassembly & Assembly Tools Needed Spanner Wrench Start By : a. Remove tilt cylinder. 3. Disconnect oil lines (4) from the tilt cylinder. Typical Example 1. Use tool (A) to remove head (1) from the cylinder body. 4. Remove retaining bolt (3), washer and head end pin (5).
  • Page 29 4. Remove the piston and seal assembly from the cylinder rod. 5. Remove the head assembly. 10. Remove O-ring seal (14) and back-up ring (15) from the head. Typical Example 6. Loosen the nut and bolt on the rod eye. Remove cylinder rod (7).
  • Page 30 NOTE : The curved side of back up ring (15) should 19. Install piston assembly (10) onto the cylinder rod. contact O-ring seal (14). 20. Install nut (9). Tighten nut (9) to a torque of 270 15. Install O-ring seal (14) and back-up ring (15) as ±...

  • Page 31: Brake Assembly

    Brake Assembly Removal & Installation 1. Put identification on the electric wires and hose assemblies as to their location on the brake valve for correct installation. 2. Press brake pedal 30times for remove (bleed) the pressure from the brake system. 6.
  • Page 32 11. Install plates (1) on the pedal plate. Vehicle System Disassembly & Assembly...

  • Page 33: Remote Control Valve

    Remote Control Valve Replacing the parts Operation Max input pressure range should be between 30 ~ 100 bar (435 ~1,450 psi) Back pressure of tank port should be less than 3 bar (43.5 psi). The oil temperature should be between -10˚C~80˚C. And, ambient temperature should be from -40˚C ~ 1.
  • Page 34 2. Replacing Pilot Pressure Spool - Loosen 4 screws holding upper part to the body - Reassemble the spool in opposite order with 3mm wrench. Hold mounting plate not to mentioned above. Insert spool as straight as spring up by return springs inside. possible not to give any damage on it while inserting it into body.

  • Page 35: Attachment Carriage

    Attachment Carriage Lift Cylinder and Mast If the lift truck is equipped with a sideshifter carriage, The rods of lift cylinders (4) are moved up by an extra valve spool is installed in the control valve. hydraulic oil pressure and returned to their original position by gravity.
  • Page 36 When the lift lever of pilot control valve is pushed forward, the cycle to lower the mast starts. The hydraulic oil pressure is released from the lift cylinder and the inner mast and carriage lower by gravity. The carriage moves down at 2:1 ratio with the cylinder rods.

  • Page 37: Hydraulic Pump

    Hydraulic Pump Removal & Installation 1. Drain the oil from the hydraulic tank. 2. Tilt the cabin. 5. Fasten a hoist to pump (7). Remove two nuts (6) and lockwashers that hold the pump in place. Remove the pump (7). The weight of the pump is 50 kg (110 lb).

  • Page 38: Start-Up Instructions & Recommendations

    Start-up Instructions & Removal of Air in Pump – Motor Recommendations line Rotation & Ports Indication The rotation and ports orientation are viewed from the shaft end. CW stands for clockwise, right-hand rotation. stands counter-clockwise, left-hand rotation. Start-up : If either main pump or fan motor is replaced in the field, be sure to apply the following bleeding The tank has been filled up with a clean fluid in process:...

  • Page 39: Pump & Cartridge Breakdown Drawing

    Pump & Cartridge Breakdown Drawing The purpose of the two screws is just to hold the cartridge together. When tightening them, check the rotation of the rotor & vane assembly. Vehicle System Disassembly & Assembly...

  • Page 40: Disassembly

    Disassembly 1. Install the pump on the table. 2. Unscrew the bolts. Two bolts in the front cap will help to unscrew the (4) pump bolts. Vehicle System Disassembly & Assembly...
  • Page 41 3. Rotate the end cap for a better prehension. 4. Remove the end cap (P3 cartridge). End Cap P3 Cartridge If the floating port plate stays in the end cap, please use two screws to take it out. Pull the 2 screws together. Vehicle System Disassembly &...
  • Page 42 5. Remove the rear port plate. 7. Remove the rotor & vane assembly. Rotor & Vane assembly Rear port plate 6. Remove the camring and the dowel pin. Cam ring Vehicle System Disassembly & Assembly...
  • Page 43 8. Remove the P2 cartridge / port block. 10. Put two screws in the housing and flip the pump (housing + P1 assy). P2 Cartridge Port block Be carefull to the cleanness of the surface. 9. Disassemble the P2 cartridge / port block with an extractor.
  • Page 44 12. Remove the front cap. 13. Disassemble the P1 cartridge / front cap with an extractor. Front cab Extractor P1 Cartridge If you wish to convert the cartridge, go to page 14. P1 cartridge will come with the front cap / A : Remove the retaining ring B : Extract the shaft / bearing assembly shaft assembly.

  • Page 45: Reassembly

    A : Protective cone on the shaft assembly Reassembly (dimensions per shaft in page 55). B : Shaft assembly + protective cone into the front 1. Fit the cartridge (P1) into the housing. C : Retaining ring. Retaining ring 2. Check if the dowel pin is in its position in the Protective cone housing by trying to rotate the cartridge.
  • Page 46 3. Assemble the front cap assy on the housing & cartridge assy. a) Always check if the shaft rotates freely. If not, disassemble and go back to the previous step. Position the shaft / front cap assy only if the b) Tighten the 4 bolts.
  • Page 47 4. Fit the cartridge (P2) into the housing. 6. Assemble the port block on the housing assy. 5. Check if the dowel pin is in its position in the housing by trying to rotate the cartridge. Put some grease on the seals to prevent them from moving.
  • Page 48 7. Install the rotor / pin / vane assembly. Install the dowel pin. Install the cam ring. Install the rear port plate. Rear port plate Cam ring Dowel pin The surface must be clean. Be sure that the port plate / cam ring are assembled with a good concentricity (to allow the end cap to fit cor-rectly.) End cap...
  • Page 49 9. Final assy. a) Always check if the shaft rotates freely. If not, disassemble and go back to the previous step. b) Check the porting configuration (refer to page 30). c) Tighten the 4 bolts. Torque is 190 N•m (140 lb•ft) Step by step to avoid damaging the seals.

  • Page 50: Seal Driver

    Seal Driver 1. Break sharp edges: 0.25/0.13 R (.010/.005 R). 2. Length to be heat treated to RC 47/50. 3. Length to have a full length, with a smooth intersection between chamfer and dia. "A". 4. Grease O.D. of length before installing the shaft seal on the tool to prevent damaging the seal.

  • Page 51: Hydraulic Oil Filter

    Hydraulic Oil Filter Disassembly & Assembly Start By : Removal & Installation a. Remove hydraulic oil filter assembly. 1. Tilt the cabin. Refer to page 25. 1. Remove four bolts (2) that hold housing (1) to head (3) 2. Disconnect three oil lines (2) 2.

  • Page 52: Universal Joint

    Universal Joint Removal & Installation Start By : a. Remove floorplate. 5. Clean enclosure bowl. Use lint free rag. 6. Inspect housing O-ring seal (7) for cut, nicks, etc. NOTE : The following steps are for the assembly of the hydraulic oil filter assembly. 7.

  • Page 53: Disassembly & Assembly

    Disassembly & Assembly NOTICE Start By : The flanges of the two yokes can be assembled out a. Remove universal Joint. of parallel. Wrong assembly of the universal joint will cause very short joint life. 8. Make an alignment of the marks on yokes (3) and (2).

  • Page 54: Steering Wheel & Gear

    Steering Wheel & Gear Removed & Disassembly of Steering Gear Steering Wheel 1. Remove all covers around the column. 2. Remove Switch Ass’y – F/R and Swith Ass’y – Combination. 3. Disconnect Gas spring and column Ass’y. NOTICE Steering gear and column can separate after bolts have all been removed, causing gear to fall.
  • Page 55 4. Disconnect (5) hoses assembled to steering unit. 5. Disassemble steering unit. 6. Install steering unit. Be sure to replace O-rings NOTE: Put identification marks on all hoses for profer with the new ones and apply the correct hose per installation.

  • Page 56: Assembly Of Steering Gear

    Assembly of Steering Gear Start By : a. Remove steering gear. 4. Remove inner gear (5), and outer gear (7). Remove the O-ring seal (8) from the outer gear. Typical Example 1. Put identification marks on the body for assembly purpose and remove fittings (1) from the steering gear.
  • Page 57 7. Remove O-ring seal (12). 11. Remove pin (18) that holds inner spool (19) in outer spool (20). Remove inner spool (19) and remove ring (21) from the outer spool. Remove springs (22) from inner spool (19). 8. Remove check valve ball (13). 9.
  • Page 58 14. Remove plugs (26), seats (27), seal-washers 17. Install springs (22) in spool (19) and install ring (21). (28), springs (29) and balls (30) from pump body (2). 18. Position inner spool (19) in outer spool (20) and NOTE : The following steps are for assembling the install pin (18).
  • Page 59 22. Install O-ring seal (12) on the pump body. Typical Example 23. Screw the threaded bush (11) lightly into the 25. Install inner gear (5) and outer gear (7). Line up check valve bore. The top of the bush must lie the marks as indicated by arrow.

  • Page 60: Steer Axle

    Steer Axle Removal & Installation Tools Needed Jack Stand Jack Stand Start By : a. Remove counter weight. 26. Install bolts (2) into cover (4). Tighten bolts (2) as follows : WARNING a. Tighten bolts (2) in correct sequence to a first torque of 15±6 N•m (132±50 lb•in).
  • Page 61 6. Remove four front mounting bolts and washers NOTICE from the steer axle. Place identification marks hydraulic 7. Pull steer axle (5) clear of the frame. Put blocks connectors and hoses to assure proper installation. under the axle to keep the axle stationary. Plug and cap all hydraulic connectors and hoses to avoid debris and contamination from entering the NOTE : The following steps are for installation of the...

  • Page 62: Steering Cylinder

    Steering Cylinder Removal & Installation Start By : a. Remove counte rweight. WARNING To prevent personal injury, move the control levers backward and forward to release any 14. Lower and pull the tool (A) from the steer axle. pressure in hydraulic system. 15.
  • Page 63 2. Remove grease nipple (2), locknut (3) and 7. Fasten a hoist to steering cylinder (6) and put in washer from bolts (4). position to the steer axle. 3. Install a 3/4"- 16 NF nut on bolt (4). Do not tighten 8.

  • Page 64: Disassembly & Assembly

    Disassembly & Assembly 1. Start the engine. Tilt the mast forward as far as possible. Stop the engine. Tools Needed Driver Group Start By : a. Remove steering cylinder. 11. Install bolt (4) into links. 12. Install washer, locknut (3) and grease nipple (2) on bolt (4).
  • Page 65 6. Inspect bushings (9) in the ends of rod (3). If a 12. Put clean hydraulic oil on seal (5) and install it on piston (6) . replacement of the bushings is needed, remove the bushings from the rod with tool (A). 13.

  • Page 66: Steering Knuckle, Kingpin And Bearings

    Steering Knuckle, Kingpin NOTICE And Bearings Be careful during installation of heads (1) to prevent Removal & Installation damage to the O-ring seal on the head. Tools Needed Driver Group Start By : a. Remove wheel bearings (steer). 18. Put one of heads (1) in position on the cylinder respective to the marks put on the heads and cylinder during disassembly.
  • Page 67 4. Remove kingpin (5). 9. Install the lower bearing (10) in the axle beam with tool (A) until the bearing is 6.4 mm (.25 in) 5. Remove knuckle (6) and thrust bearing (7) from the axle beam. below the surface that makes contact with the steering knuckle.
  • Page 68 13. Put knuckle (6) and thrust bearing (5) in position 16. Pull the links into position. Install bolt (3) in the on the axle. Make sure the outer metal shell of links and knuckle. the thrust bearing is next to the axle (away from the knuckle).

  • Page 69: Steer Tire And Rim

    Steer Tire And Rim Removal of Wheel Bearing Removal & Installation Tools Needed Driver Group 1. Put a hydraulic jack in position under the steer axle. 1. Put a jack in position under the steer axle. Lift the truck until the steer tire is clear of the ground. 2.

  • Page 70: Installation Of Wheel Bearing

    Installation of Wheel Bearing Tools Needed Wrench 4. Remove outside nut (4) with tool (A). 5. Remove the tine (tab) on washer (3) out of the head in inside nut (5). 6. Remove washer (3) and inside nut (5) from the 1.

  • Page 71: Drive Tire And Rim

    Drive Tire And Rim 5. Put (pack) clean grease in the outer bearing cone (6). Install the outer bearing cone (6) on the steering knuckle. Removal & Installation 6. Install washer (3) and inside nut (5) on the steering knuckle Tools Needed Socket 7.

  • Page 72: Counterweight

    5. Put the inner tire and rim (2) in position on the 3. Remove bolts (2), and washers that hold the forks of a power truck. Put the tire and rim in counterweight to the frame. Remove the position on the hub. counterweight.

  • Page 73: Removal Of Air

    Removal of Air After changing main pump Pump – Motor line Charging Valve If either main pump or fan motor is replaced in the PM Port field, be sure to apply the following bleeding process: If either main pump or fan motor is replaced in the field, be sure to apply the following bleeding process.

  • Page 74: Air In Brake System

    Air in Brake system Removal of the High Pressure in accumulator Needle Valve Screw Charging Manifold If you feel the brake pedal soft like a piece of sponge, there is air in the brake hydraulic system. The root cause can be low brake fluid level, brake WARNING fluid leakage, damaged brake line or disconnected brake line.

  • Page 75: Emergency Lowering

    Emergency Lowering Emergency control screw for lowering the lift WARNING If you cannot lower the carriage by pushing the lift lever, you can lower it by using the emergency descending control screw on the main control valve. When lowering the carriage by this method, it is very dangerous to stay beneath or near the carriage.

  • Page 76: Removal And Installation Of Engine And Transmission

    Removal and installation of Engine and Transmission. Stand by : a) Remove the mast Refer to the topic of Mast in this module for the further information. b) Remove the drive tire c) Drain the transmission oil d) Drain the engine oil. e) Drain the coolant.
  • Page 77 4. Fasten a hoist to hook position like the above 7. Remove the bolt and washer (1) after hosting the picture. (1500kg) transmission with Crane after disassembling the hoses. (1500kg) 5. Dismount the Engine and transmission. 8. Disassemble the transmission from Engine. 9.

This manual is also suitable for:

D130s-5 with ocdbD160s-5 with ocdb

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