Doosan Power Train D50S-5 Specifications Systems Operation Testing & Adjusting Disassembly & Assembly
Doosan Power Train D50S-5 Specifications Systems Operation Testing & Adjusting Disassembly & Assembly

Doosan Power Train D50S-5 Specifications Systems Operation Testing & Adjusting Disassembly & Assembly

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Power Train
Specification
System Operation
Testing & Adjusting
Disassembly & Assembly
D50S-5, D60S-5, D70S-5, D80S-5, D90S-5
G50S-5, G60S-5, G70S-5
Two Speed Transmission
Drive Axle (OCDB, SHOE)
SB4274E00
Sep. 2007

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Summary of Contents for Doosan Power Train D50S-5

  • Page 1 SB4274E00 Sep. 2007 Power Train Specification System Operation Testing & Adjusting Disassembly & Assembly D50S-5, D60S-5, D70S-5, D80S-5, D90S-5 G50S-5, G60S-5, G70S-5 Two Speed Transmission Drive Axle (OCDB, SHOE)
  • Page 2 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, Iubrication, maintenance or repair procedures you choose.
  • Page 4: Table Of Contents

    Index Specification Wheel Brake Adjustment ........30 General Tightening Torque ........5 Inching Pedal Adjustment ........32 Drive Axle Specification ........6 Torque Converter..........7 Disassembly and Assembly Transmission Pump ..........7 Drive Axle Mounting..........8 Differential ............8 Drive Shaft and Universal Joint......35 Wheel Bearing and Drive Wheel ......
  • Page 6: Specification

    Specification General Tightening Torque GENERAL TIGHTENING TORQUE FOR BOLTS, NUTS AND TAPERLOCK STUDS The following charts give the standard torque values for bolts, nuts and taperlock studs of SAE Grade 5 of better quality. Exceotions are given in other sections of Service Manual where needed. THREAD DIAMETER STANDARD TORQUE inches...
  • Page 7: Drive Axle Specification

    Drive Axle Specification Shoe Type 2.636 / D(G) 50/70S-5 Differential 3.100 / D80/90S-5 Gear Ratio Planetary 10.545 / D(G) 50/70S-5 Drive Axle Total 12.400 / D80/90S-5 Axle Oil SAE #80 or #90 Oil Volume 12.5 L Service Brake Shoe Brake Brake Brake Oil AZOLLA - ZS10...
  • Page 8: Torque Converter

    Torque Converter Transmission Pump (1) Clearance between outside of drive gear and crescent 0.36 to 0.43 mm (0.014 to 0.017 in) (1) Torque for bolts (plate to torque converter) ........45 ± 7 N∙m (33 ± 5 lb•ft) Apply LOCTITE NO. 277 sealant to threads of bolts.
  • Page 9: Drive Axle Mounting

    3. Apply Loctite No.271 to threads of bolts. Drive Axle Mounting Torque for bolts..157 ± 5 N•m (116 ± 4 lb•ft) Consider same marking on brackets to the housing. 4. Apply Loctite No.271 to threads of bolts. Torque for bolts....10 ± 2 N•m (7 ± 2 lb•ft) 5.
  • Page 10: Brake Assembly

    Slotted nut adjustment Brake Assembly a. Tighten slotted nut (1) slightly by hand. b. Tighten slotted nut (1) to 640 N•m (472 lb•ft). c. Rotate wheel hub several times. d. Turn back slotted nut (1) slightly and retighten until bearing friction torque reaches to 10~14 N•m (7.4 to 10.3 lb•ft).
  • Page 11: Brake Drum Diameter

    Brake Drum Diameter Brake drum diameter (1) .... 315.0 to 315.2 mm (12.402 to 12.409 in) Maximum total diameter of brake drums which can be machined from the original diameter..2.0 mm (0.079 in) U - joint Torque for bolts (1) ........55 ± 7 N•m (40 ±...
  • Page 12: System Operation

    System Operation General Information (1) Engine (2) Torque Converter (3) Power Shift Transmission (4) Universal joint (5) Drive Axle (6) Drive Wheels. The basic components of the power train are: Power from the transmission is sent through its engine (1), torque converter (2), power shift output gear through the drive shaft and reduction transmission (3), universal joint (4), drive axle (5), gears to the differential.
  • Page 13: Power Shift Transmission

    Power Shift Transmission In the power flow diagrams that follow, the components are shown in a position to make it General Information easier to follow the power flow through the transmission. Illustration shows the transmission The transmission is a constant mesh power shift from the converter end with the correct location of transmission and gives two forward and two the components.
  • Page 14: Power Flow At Low Speed Forward

    Power Flow at Low Speed Forward SECTION : A-A Power Flow In Low Speed Forward (1) Input Shaft. (2) Cylinder Clutch(Forward). (7) Piston. (10) Intermediate Shaft. (11) Gear(Low). (12) Intermediate Shaft Gear. (13) Gear(High). (14) Output Shaft. (15) Output Shaft Gear. (16) Clutch(Forward low). (18) Valve Ass’y (19) Yoke. (20) Gear(Forward high).
  • Page 15: Power Flow At High Speed Forward

    Power Flow at High Speed Forward SECTION : A-A Power Flow In High Speed Forward (1) Input Shaft. (2) Cylinder Clutch(Forward). (7) Piston. (10) Intermediate Shaft. (11) Gear(Low). (12) Intermediate Shaft Gear. (13) Gear(High). (14) Output Shaft.. (15) Output Shaft Gear. (16) Clutch(Forward low). (18) Valve Ass’y (19) Yoke. (20) Gear(Forward High).
  • Page 16: Power Flow At Low Speed Reverse

    Power Flow at Low Speed Reverse SECTION : B-B Power Flow In Low Speed Reverse (1) Input Shaft. (2) Clutch Cylinder Gear(Forward). (3) Clutch Cylinder Gear(Reverse). (4) Reverse Shaft. (5) Gear(Reverse low). (6) Clutch(Reverse low). (7) Piston. (8) Clutch(Reverse high). (9) Gear(Reverse high). (10) Intermediate Shaft. (11) Gear(Low).
  • Page 17: Power Flow At High Speed Reverse

    Power Flow at High Speed Reverse SECTION : B-B Power Flow In High Speed Reverse (1) Input Shaft. (2) Clutch Cylinder Gear(Forward). (3) Clutch Cylinder Gear(Reverse). (4) Reverse Shaft. (5) Gear(Reverse low). (6) Clutch(Reverse low). (7) Piston. (8) Clutch(Reverse high). (9) Gear(Reverse high). (10) Intermediate Shaft.
  • Page 18: Transmission Control Valve

    Transmission Control Valve Cross-Section View RELIEF VALVE INCHING VALVE ACCUMULATOR VALVE F1 F2 SOLENOID VALVE SECTION "B-B" (1) BODY. (2) SPOOL. (3) SPRING. (4) PLUG. (5) O-RING. (6) ORIFICE. (7) STOPPER. (8) O-RING. (9) SPRING. (10) PISTON. (11) PLUG. (12) FILTER ASS'Y. (13) O-RING. (14) SPOOL. (15) SPRING. (16) SPRING. (17) PLUNGER. (18) PIN.
  • Page 19: Hydraulic Schematic

    Hydraulic Schematic (1) RELIEF VALVE. (2) INCHING VALVE. (3) ACCUMULATOR VALVE. (4) SOLENOID VALVE. (1) RELIEF VALVE ◆ OPERATION The oil from the PUMP is fed to VALVE via “A.” ◆ FUNCTION To maintain constant pressure in the CONTROL As pressure rises, the oil through “A” overcomes VALVE, preventing excessive rise or fall of the spring force and pushes SPOOL to left.
  • Page 20 (2) INCHING VALVE ◆ FUNCTION The INCHING VALVE controls the pressure of oil entering CLUTCH and smoothens the CLUTCH contact. In addition, by enabling the vehicle to move smoothly at high RPM, it provides fast functionality of the implement in low speed. Therefore, wash the plug when replacing the T/M oil.
  • Page 21: Differential And Drive Axles

    Differential and Drive Axles When the machine moves straight forward, traction Differential under each wheel is the same, so the torque from each axle is the same and pinions (3) do not turn on spider (6). This gives the same effect as if both wheels were the same axle.
  • Page 22: Brake Components

    Brake Components Shoe Brake Brake Adjuster Brake Adjuster (1) Adjusting Bolt. (2) Sleeve. (3) U-shaped Bracket. (4) Adjusting Lever. (5) Adjusting Screw. (6) Spring. (1) Wheel Cylinder. (2) Wheel Cylinder Pistons. (7) Adjusting Wheel. (8) Spring. (3) Secondary Shoe. (4) Return Springs. (5) Primary Shoe. (6) Return Spring.
  • Page 23: Ocdb

    OCDB (1) Spindle. (2) Steel plate. (3) Disk plate. (4) Service piston. (5) Drive shaft. (6) Service piston adjust bolt. (7) Spline collar. (8) Parking brake. Sealed up structure of hydraulic disk brake system secures good brake performance even in the high humid or dusty area.
  • Page 24: Testing And Adjusting

    4. Check the strainer behind the transmission oil plug Testing and Adjusting and the filter foreign material. a. Particles of friction paper material give an indication of a clutch failure. Troubleshooting b. Metallic(metal) particles in the filter give an Troubleshooting can be difficult. A list of possible indication of wear or mechanical failure in the problems and corrections is on the pages that follow.
  • Page 25 e. Converter drive tangs worn off or not engaged 9. Too much stalling of torque converter. into pump. 10. Cooler bypass valve stuck (held) open, full oil f. Main regulator valve stuck open. flow does not go through oil cooler. g.
  • Page 26: Check List From Operation Noise

    b. Leakage caused by worn or broken seal Problem : Vehicle operates in one direction and around clutch piston. creeps in that direction in NEUTRAL. Engine stalls when shifted to the other direction. c. Failure of other components. Probable Cause : 4.
  • Page 27: Check List From Pressure Test

    Problem : Noise in the control valve. Problem : Low main line pressure. Probable Cause : Probable Cause : 1. Air in the hydraulic system. 1. Low oil level. a. Air leakage on suction side of the pump. 2. Main regulator valve movement is restricted. b.
  • Page 28: Differential

    Problem : Low converter pressure. Problem : Noise at different intervals. Probable Cause : Probable Cause : 1. Main regulator valve movement is restricted. 1. Ring gear does not run even. a. bolts on drive gear not tightened correctly. Problem : Converter outlet pressure or cooler b.
  • Page 29: Transmission Pressure

    Transmission Pressure ICPS054S (1) Forward low clutch pressure tap. (2) Forward high clutch pressure tap. (3) Reverse low clutch pressure tap (4) Reverse high lutch pressure tap. (5) Main line pressure tap. (6) Converter pressure tap. Transmission Pressure Main Line Converter Forward Low Forward High...
  • Page 30: Converter Stall Test

    2. Engage the wheel brakes and push the Converter Stall Test accelerator pedal down completely. Read the RPM on he tachometer, then release the The converter stall test is a test to check engine accelerator pedal. Turn the speed control lever to power.
  • Page 31: Shimming Of Transmission Shaft

    9. If you reshim input shaft or counter shaft, turn Shimming of Transmission Shaft transmission input shaft by hand. It should be turned smoothly. If you reshim intermediate shaft 1. Assemble shaft assembly (including taper bearing or output shaft, turn output shaft by hand. It cone and cup).
  • Page 32 Setting Procedure CAUTION During setting, the parking brake must be released. The cable should not be tensioned. Correction of wheels which are not equally difficult to turn may only be carried out at the 1. Jack up the vehicle brake cables and not at the automatic adjuster. 2.
  • Page 33: Inching Pedal Adjustment

    Inching Pedal Adjustment WARNING To prevent personal injury, when the inching To check the inching valve adjustment and pedal is adjusted, move the truck to a clear area operation, do the procedure that follows : that is level. Keep all other personnel away from the lift truck.
  • Page 34 The adjusting procedure is as follows. Be sure that the air bleeding of brake system should be done in advance. < OCDB > 2. Adjust the length (B) of rod by fixing the nuts at both ends. (B) is about 100 mm. <...
  • Page 35 5. The stroke of inching spool when the brake pedal is engaged should be 3 ± 1 mm. 6. Before doing the truck test, inspect again all relevant dimensions. 7. Inspect the service brake and then, inching operation. Power Train Testing and Adjusting...
  • Page 36: Disassembly And Assembly

    6. Connect the other of the drive shaft (3) to the Disassembly and transmission yoke (2) and, fasten with four bolts Assembly (1). NOTE : Tighten all bolts that fasten universal joints to a torque of 60 ± 7 N•m (45 ± 5 lb•ft). Drive Shaft and Universal Joint End By: Remove Drive Shaft and Universal Joint...
  • Page 37: Engine, Torque Converter And Transmission

    Engine, Torque Converter and NOTICE Transmission The flanges of the two yokes can be assembled out of parallel. Wrong assembly of the universal joint will cause very short joint life. Assemble the spline yoke Remove & Install Engine, Torque into the slip yoke. Both flanges mush be parallel. Converter and Transmission Start By: a.
  • Page 38 4. Disconnect two cooling lines (8). 5. Disconnect two cooling lines (9). 6. Remove two water cooling lines (10). 7. Remove engine harness assembly (11). 9. Loosen bolts (14) and nuts (18). Remove muffler and exhaust tube assembly (15). 10. Remove radiator reservoir hose (19). 11.
  • Page 39 12. Remove bolts (20) and nuts from engine mounts. NOTICE Make sure the engine is supported underneath by suitable wooden blocks. Failure to support engine will result in possible damage. 13. Remove engine and transmission with a hoist. 14. Install the engine and transmission in the reverse order of removal.
  • Page 40 Separation of Torque Converter and Connection of Torque Converter and Transmission from Engine Transmission to Engine Start By: a. Remove engine, torque converter and transmission. 1. Put the transmission and torque converter (5) into position and make a connection of the transmission and torque converter.
  • Page 41: Transmission Control Valve

    Transmission Control Valve Disassembly of Transmission Control Valve 3. Disassemble Accumulator Valve a. Disassemble the Plug (11) fitted with filter, O- Ring (13)(31), and Spring(9) from main body. b. Disassemble Stopper (7) and O-Ring (8) from main body. 1. Disassemble Solenoid Valve a.
  • Page 42 Assembly of Transmission Control Valve 1. Preparation for Assembling a. Refer to the valve disassembling/assembling procedure in advance. b. Arrange the work area. c. Prepare assembling tools. d. Prepare necessary parts according to the number of valves to be assembled. 3.
  • Page 43 CAUTION Be Sure that the SEAL is not twisted. 5. Assemble Inching Valve a. Assemble Body with Spool (14), Spring (31), Spring (15), and Spring (16) in the said order. Insert Plunger and push it down, insert Pin (18) and tighten with Stop Bolt (19). (Stop Bolt must not project from the bottom surface).
  • Page 44: Transmission

    Transmission Disassembly of Transmission 4. Isolate plug (20), O-ring, spring (21) and ball (22) from cover. 5. Disassemble plug (18), O-ring, spring (17) and spool (16). 1. Isolate torque converter from housing. Remove 6 bolts (3) from the torque converter, isolate plate(2) 6.
  • Page 45 7. Unscrew 5 bolts (11) from the Stator Hub (12) 9. From the bearing plate (14), isolate 2 thrust fixed on the Bearing Plate (14), and isolate them washers (31), needle bearing (32), and Gear- P.T.O Idle (33). from the plate. Use rubber hammer to protect Stator Hub from damage.
  • Page 46 12. Isolate plug (41) and O-ring. Disassemble spring 17. Disassemble 2 thrust washers (48) and gear (39) and oil screen (40) from the case (49) 18. Disassemble needle bearing and washer from front shaft of the high speed clutch face 13.
  • Page 47 21. Push down the retainer (53) with pressure. 26. Disassemble 2 thrust washers (59) and pin (57). Isolate snap ring (52) with a screw driver. Remove the tension force on the assembly 27. Push retainer (53) down with press and remove slowly.
  • Page 48 CAUTION When removing the spacer, take care not to tear the O-ring in the spacer. 30. Remove bearing cone(71) and gear(72) from the intermediate gear using puller. Remove the bearing cone(73) on the opposite side in the same manner. CAUTION 33.
  • Page 49 Assembly of Transmission 7. Install spring assembly and retainer (53) in the cylinder. 1. Wash all the parts clean. Apply transmission oil 8. Place the shaft assembly on press. Press down on all the parts. the retainer, and assemble snap ring (52) using a 2.
  • Page 50 12. Install the pressure plate at its place in the cylinder. 13. Assemble the pressure plate at its place in the cylinder, mount the snap ring (50) using a screw driver. 14. Assemble 3 seal rings on the shaft. CAUTION Take care not to damage the seal ring in the counter shaft.
  • Page 51 21. Mount gear (72) on the intermediate gear. 23. Install tube (45) on the transmission case with Assemble bearing cone (71) with press. plastic hammer. Assemble the bearing cone (73) on the opposite side in the same manner. 24. Assemble backward shaft and input power shaft in the following procedures.
  • Page 52 28. Assemble the oil screen (40), spring (39), plug 31. For the bearing plate (14), assemble thrust 2 (41) and O-ring in the transmission case. washers (31), needle bearing (32), and Gear- P.T.O Idle (33). 29. Apply Loctite #5172 on the gasket surface of the case, and fix it.
  • Page 53 33. Assemble Stator Hub assembly (12), bush (13), piston ring, and 6 bolts (11), and assemble them with the bearing plate (14). 39. When using a new part, calculate the shim thickness as follows. 34. Assemble plug (15) and O-ring on the Measuring method of shim on shaft transmission cover.
  • Page 54 e. Set the transmission assembly vertically. f. Check the shim adjustment on the input and counter shafts. The input shaft of the transmission must be able to rotate freely. g. If the input or output shaft does not rotate freely, remove 0.025~0.05㎜...
  • Page 55: Drive Axle

    Drive Axle Disassembly 4. Loosen cylindrical bolts and remove planetary carrier. Detach and remove O-ring from axle hub. 1. Drain oil after loosening drain plug with a torque wrench (1) 5. Remove snap ring (5) from the housing of planetary 2.
  • Page 56 7. Remove needle bearing (8), planetary gear (7) 10. After removing bolt (13), remove ring gear (14) and thrust washer (9). and torque plate assembly from the axle tube. 11. Remove snap ring from the ring gear (14) and 8. Remove sun gear (10) and drive shaft (11). disassemble internal gear carrier 9.
  • Page 57 Removal and Strip Down of Brake Removal and Strip Down of Axle Housing 1. Remove 2 tension springs with the aid of pliers or a screwdriver 1. Loosen 12 bolts (1) and then, remove carrier from the housing by using a lifting machine. 2.
  • Page 58 5. Disassemble bearing (7) from the differential 9. Remove thrust washer, side gear, pinion gear and housing and remove 12 bolts (8). spider and then, place them on the clean bench. 10. Loosen 4 bolts (10) and then, remove Drum from 6.
  • Page 59 CAUTION Be careful not to damage bevel pinion shaft. 16. Remove outer race of taper roller bearing from the opposite side. Reassembly of Drive Axle 14. Remove shim (16) and spacer (17) from pinion Clean all of the parts with cleanser and then, shaft.
  • Page 60 Adjustment of Bevel Pinion Shaft 2. Using different kinds of shims, adjust shim thickness as measured by previous equation. Adjusting shim of bevel pinion shaft. Place shims at the bearing place. Using a jig, assemble drive bearing so that the outer race 1.
  • Page 61 Adjustment of Pinion Shaft 1. Assemble bearing cup. Assemble spacer to the pinion shaft and then, install measured shims onto the spacer. Measure shim thickness by following method. Dimension "Q" : Distance from bearing outer race surface to spacer surface. Dimension "S"...
  • Page 62 Assembly of Differential CAUTION Check marks on the housing. Match two marks at the same position. 1. Assemble thrust washer, side gear and spider gear and then, install them to the differential housing. Apply grease on the bevel gear and thrust washer.
  • Page 63 At this moment, by adjust rotation backlash. By Assembling Carrier Install the dial gauge on the gear tooth and measure the backlash while rotating bevel gear. • Rotation backlash : 0.18~0.23 ㎜ 6. Assemble bearing cap. CAUTION Fix bearing cap with hexagon bolt. •...
  • Page 64 2. Lead brake cable through the provided borehole 2. Install wheel hub assembly to the tube flange of of the brake carrier and hook it on the pressure axle completely. Install bearing cone. rod of the brake shoes. Assemble brake shoes, compression springs and tension springs as described in the Dosassembly Section in reverse order.
  • Page 65 7. Assemble wheel hub and tighten plug (1). • Tightening torque : 35~59 N•m (25~44 lb•ft) 5. Assemble internal components of planetary carrier in the reverse order of disassembly. 8. Install brake drum and tighten the bolts. Assembling Wheel Hub Ass’y (OCDB) 6.
  • Page 66 2. Install wheel hub assembly to the tube flange of 5. Insert shim, fix the torque plate and ring gear with axle completely. Install bearing cone. snap ring and assemble them to the axle tube. Apply loctite #271 or #277 to thread of bolt (2) and then, assemble at the tightening torque of ........
  • Page 67 Assembling OCD Brake 8. After assembling sun gear (9) to axle shaft, fix it with snap ring (10). Assemble axle shaft to the axle assembly. Apply grease on the shaft where bushing contcts. Apply grease to teeth parts of planetary gear. 7.
  • Page 68 10. Install planetary carrier assembly to wheel hub and tighten bolt *Tightening torque : 25~39 N•m (18~29 lb•ft) 11. Assemble wheel hub and tighten plug (1). • Tightening torque : 35~59 N•m (25~44 lb•ft) Power Train Disassembly and Assembly...

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