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Doosan D110S-5 Specifications, Systems Operation, Disassembly & Assembly

Lift trucks power train-drive axle
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Table of Contents

Specifications
Systems Operation
Disassembly & Assembly
Lift Trucks Power Train-Drive Axle
D110S-5
D130S-5
D160S-5
D100
( EM083-00034~UP )
D120
( EM084-00023~UP )
D150
( EM086-00023~UP )
SB4013E01
N o v. 2 0 0 6

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Summary of Contents for Doosan D110S-5

  • Page 1 SB4013E01 N o v. 2 0 0 6 Specifications Systems Operation Disassembly & Assembly Lift Trucks Power Train-Drive Axle D110S-5 D130S-5 D160S-5 D100 ( EM083-00034~UP ) D120 ( EM084-00023~UP ) D150 ( EM086-00023~UP )
  • 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 Specifications Axle for D100/120 & D110/130S-5 Truck-Wheel end Torque Chart ............5 Axle for D150 & D160S-5 Truck-Wheel end Torque Chart ..............6 Systems Operation Drive Axle..............7 Standard Single Reduction Carriers ......8 Disassembly & Assembly Brakes ..............62 Differential ..............9 Wheel end..............43 Axle for D100/120 &...

  • Page 7: Specifications

    Specifications Axle for D100/120 & D110/130S-5 Truck-Wheel End Torque Chart Item Fastener Torque Value Wheel rim nut 500 lb•ft (680 N•m) pinion shaft set screw 35 lb•ft (47 N•m) Oil fill/level/drain plug 35 lb•ft (47 N•m) planetary spider-to-wheel hub slotted head screw Hand tighten(no specification) Spindle and brake spider mounting 310-400 lb•ft (420-542 N•m)

  • Page 8: Axle For D150 & D160S-5 Truck-Wheel End Torque Chart

    Axle for D150 & D160S-5 Truck-Wheel End Torgue Chart Item Fastener Torque Value Wheel rim nut 500 lb•ft (680 N•m) Lock plate screw 20-30 lb•ft (27-41 N•m) Planetary spider cover 35-50 lb•ft (48-68 N•m) Wheel bearing adjusting nut Refer to instrucitions on page 59 Planetary spider-to-wheel hub slotted head screw Hand tighten (no specification) Camshaft bracket to spider...

  • Page 9: Systems Operation

    Systems Operation • The planetary gears rotate on planetary shafts which are mounted on a spider. The planetary gear teeth in turn mesh with teeth of the floating ring Drive Axle gear. • Power is transmitted by the hypoid gear set in the carrier to the axle shafts and the sun gear of the final reduction, through the revolving planetary gears, and into the planetary spider which drives...

  • Page 10: Standard Single Reduction Carriers

    Standard Single Reduction A straight roller bearing (spigot) is mounted on the head of the drive pinion. All other bearings in the Carriers Without Differential carrier are tapered roller bearings. Lock When the carrier operates, there is normal differential action between the wheels all the time. The single reduction carrier models are front mounted into the axle housing.

  • Page 11: Disassembly & Assembly

    Disassembly & Assembly Removal of the Differential Carrier from Axle Housing WARNING To prevent serious eye injury, always wear safe eye protection when performing vehicle maintenance or service. 1. Make sure vehicle is on level surface. 5. Disconnect the driveline universal joint from the 2.
  • Page 12 Carrier Removal from Axle CAUTION : When using a pry bar be careful not to damage the carrier or housing flange. Damage to these surfaces will cause oil leaks. 1. Place a hydraulic roller jack under the differential carrier to support the assembly. 6.
  • Page 13 Remove the Differential and Ring Gear from the Carrier 1. Loosen the jam nut on the thrust screw. 2. Remove the thrust screw and jam nut from the differential carrier. 3. Rotate the differential carrier in the repair stand NOTE : Before working on the differential carrier, until the ring gear is at the top of the assembly.
  • Page 14 5. Remove the cotter keys that hold the two bearing adjusting rings in position. 6. Remove the capscrews and washers that hold the two bearing caps on the carrier. Each cap is held in position by two capscrews and washers. 7.
  • Page 15 Disassemble the Differential and Ring Gear Assembly WARNING Do not hit steel parts with a steel hammer during removal and disassembly procedures. Striking 1. If the matching marks on the case halves of the parts with a hammer can cause the parts to break differential assembly are not visible, mark each and result in serious personal injury.
  • Page 16 Remove the Drive Pinion and Bearing Cage from Carrier WARNING 1. Fasten a yoke bar to the input yoke. When the nut is removed, the bar will hold the drive pinion in Observe all WARNINGS and CAUTIONS provided position. by the press manufacturer concerning press operation to avoid serious personal injury and 2.
  • Page 17 Disassemble the Drive Pinion and Bearing Cage WARNING Do not hit steel parts with a steel hammer during removal and disassembly procedures. Striking parts with a hammer can cause the parts to break and result in serious personal injury. WARNING Observe all WARNINGS and CAUTIONS provided by the press manufacturer concerning press CAUTION : Do not use a pry bar to remove the...
  • Page 18 Be careful that you do not damage the mounting surfaces of the bearing cage. 1. Place the drive pinion and bearing cage in a press. The pinion shaft must be toward the top of the assembly. 2. Support the bearing cage under the flange area with metal or wood blocks.
  • Page 19 7. If the pinion bearings need to be replaced, remove 10. Remove the spigot bearing from the drive pinion the inner bearing cone from the drive pinion with a with a bearing puller. press or bearing puller. The puller must fit under the inner race of the cone to remove the cone correctly without damage.
  • Page 20 Assemble the Drive Pinion, Bearings and Bearing Cage WARNING To prevent serious eye injury, always wear safe eye protection when performing vehicle maintenance or service. WARNING Observe all WARNINGS and CAUTIONS provided by the press manufacturer concerning press operation to avoid serious personal injury and possible damage to components during assembly and installation procedures.
  • Page 21 6. Place the drive pinion in a press, gear head (teeth) 9. Apply axle lubricant to the bearing cups and to the toward the top. bearing cones in the cage. 7. Press the spigot bearing on the end of drive pinion 10.
  • Page 22 Adjusting Preload of Pinion a. Place the drive pinion and cage assembly in a press, gear head (teeth) toward the bottom. Bearings b. Install a sleeve of the correct size against the inner race of the outer bearing. Specifications c. Apply and hold the correct amount pressure to the pinion bearings.
  • Page 23 j. If the preload (torque) of pinion bearings is not within specifications, do the following procedure then repeat steps a through i. To increase preload, install a thinner bearing spacer. To decrease preload, install a thicker bearing spacer. k. Inspect the bearing preload with the drive pinion and cage assembly installed in the carrier.
  • Page 24 CAUTION : Do not install tight fit yokes on shafts using a hammer or mallet. A hammer or mallet will damage the yoke. b. Temporarily install the drive pinion and cage assembly in the carrier. Do not install shims under the bearing cage.
  • Page 25 11. Install a new triple-lip seal as follows. a. Apply the same lubricant used in the axle housing to the outer surface of the seal and the seal bore in the bearing cage. CAUTION : Make sure that the seal lips are clean and free from dirt and particles that will cause a leak c.
  • Page 26 Adjusting Shim Pack Thickness for a New Drive Pinion (Depth of Pinion) NOTE : If a press is not available, use a mallet and the sleeve or driver to install the seal. WARNING Do not hit steel parts with a steel hammer during removal and disassembly procedures.
  • Page 27 6. If the new pinion cone (PC) number in a rear differential carrier is a plus (+) number, add the number to the standard shim pack thickness that was calculated in step 3 or 4. 7. If the new pinion cone (PC) number in a rear differential carrier is a minus (-) number, subtract the number from the standard shim pack thickness that was calculated in step 3 or 4.
  • Page 28 NOTE : The value calculated in step 6 or 7 is the 8. Install the drive pinion, bearing cage and new shim thickness of the new shim pack that will be installed. pack into the carrier. Refer to the following examples. Examples: Inches 1.
  • Page 29 Installing the Drive Pinion, Bearing Cage and Shim Pack into the Carrier NOTE : If a new drive pinion and ring gear set is installed, or if the depth of the drive pinion has to be adjusted, calculate the thickness of the shim pack. Refer to the procedure “Adjusting Shim Pack Thickness for the pinion Cage (Depth of Pinion)”...
  • Page 30 Installing Tight Fit Yokes and the POSE Seal CAUTION : Make sure that the seal lips are clean and free from dirt and particles that can cause a leak between the yoke and the POSE seal. CAUTION : Do not use a hammer or mallet to install the yoke to the input pinion shaft.
  • Page 31 7. Tighten the bolts and nuts to a torque of 196 to WARNING 262 lb•ft (265 to 355 N•m) a. After the bolts are installed, inspect for gaps Wear safe clothing and gloves for protection from between the back surface of the ring gear and the injury when working with the hot ring gear.
  • Page 32 13. Install the second side gear and thrust washer over spider and differential pinions. 9. Apply axle lubricant on the inside surfaces of both case halves, spider (cross), thrust washers, side gears and differential pinions. 10. Place the flange case half on a bench, ring gear teeth toward top.
  • Page 33 Checking the Rotating Resistance of the Differential Gears 15. Install Dri-Loc fasteners into the case halves. Refer to the following steps a and b. NOTE : Make a tool for inspecting the rotating a. Install four capscrews and washers into the case resistance of the differential gears.
  • Page 34 Install the Differential and Ring Gear Assembly 4. Attach a wrench to the nut of the tool and rotate 1. Clean and dry the bearing cups and bores of the the differentail gears. The differential assembly carrier legs and bearing caps. must freely rotate.
  • Page 35 CAUTION : If bearing caps are not installed in correct locations, the bores and threads in caps will not match the carrier. You will have problems assembling the caps on the carrier and damage to parts can occur. Do not force the bearing caps into position.
  • Page 36 Adjust Preload of Differential Bearings Specifications • Preload of differential bearings – 15 to 35 lb-in (1.7-3.9 N•m) torque. • Expansion between bearing caps (leg spread) – 0.002 to 0.009 inch (0.050-0.229 mm) Dial Indicator Method Use the dial indicator or the large micrometer method for checking and adjusting the preload of the main differential side bearings.
  • Page 37 Large Micrometer Method A second method of inspecting preload is to measure the expansion between the bearing caps (leg spread) after the adjusting rings are tightened. Use the following procedure. b. Use two pry bars between the differential case or ring gear and the carrier at locations other than described in step a.
  • Page 38 4. Measure the distance X or Y again. Compare the 2. Adjust the dial indicator so that the plunger or dimension with the distance X or Y measured in pointer is against the back surface of the ring gear. step 2. The difference between the two dimensions is the amount the bearing caps have expanded 3.
  • Page 39 NOTE : Backlash is increased by moving the ring gear away from the drive pinion. 1. Attach a dial indicator on the mounting flange of the carrier. 2. Adjust the dial indicator so that the plunger or pointer is against the tooth surface. 3.
  • Page 40 Inspecting Tooth Contact Tooth Contact Patterns of Generoid Hypoid Gear Sets Patterns (Backlash) of the Gear Set 1. Adjust the backlash of a new gear set to 0.012 inch (0.300 mm). In the following procedures, movement of the contact 2. Apply a marking compound to approximately 12 pattern in the lenght of the tooth is indicated as gear teeth of the ring gear.
  • Page 41 Hypoid Generoid Gears The location of a good hand-rolled contact pattern for an old gear set must match the wear pattern in the ring gear. The new contact pattern will be smaller in area than the old wear pattern. If the contact patterns require adjustment, continue by following step 5 to move the contact patterns between the top and bottom of the gear teeth, If the contact patterns are in the center of the gear...
  • Page 42 6. Adjust backlash of the ring gear within specification range to move the contact patterns to the correct location in the length of the gear teeth. Refer to the procedure on page 36. a. Decrease backlash to move the contact patterns a.
  • Page 43 Install cotter keys between lugs of the adjusting ring and through the boss of the bearing cap. Bend the two ends of the cotter key around the boss. 3. Loosen the thrust screw 1/2 turn,180˚. Install and Adjust the Thrust Screw Specification •...
  • Page 44 Install Differential carrier into Axle Housing WARNING Be careful when using cleaning solvents. Follow the solvent manufacturer’s instructions for safe use to prevent injury. 1. Clean the inside of axle housing and the mounting surface where the carrier fastens. Use a cleaning solvent and rags to remove dirt.

  • Page 45: Wheel End

    Wheel End Axle for D100/120 Truck Item Description Q’ty Item Description Q’ty Item Description Q’ty Brake Drum Snap Ring Wheel Nut Magnetic Fill/Drain Plug Snap Ring Wheel Stud Planetary Spider Assembly Planetary Sun Gear Hub and Cup Assembly Set Screw Thrust Washer Inner Bearing Cup Machine Screw...
  • Page 46 Axle for D150&160S-5 Truck Item Description Q’ty Item Description Q’ty Item Description Q’ty Brake Drum Thrust Washer O-Ring Mangetic Fill/Dran Plug Snap Ring Hub and Cup Assembly Planetary Assembly Cover Planetary Sun Gear Wheel Nut Capscrew Thrust Washer Wheel Stud Hardened Washer Wheel Bearing Nut lnner Bearing Cup...

  • Page 47: Axle For D100/120 & D110/130S-5 Truck

    Axle for D100/120 & Remove the Brake Drum D110/130S-5 Truck WARNING Remove and Disassemble the Axle Block the wheels to prevent the vehicle from moving. Wheel End Support the vehicle with safety stands. Do not work under a vehicle that is supported only by jacks. NOTE : Numbers in parenthesis ( ) refer to the Axle Jacks can slip or fall over.
  • Page 48 4. Remove the wheel nuts and dual tire/rim assemblies from both wheel ends. 5. Rotate the wheel ends so the magnetic drain plug (2) in the planetary spider (3) is at the bottom. Remove the plug. Drain and discard the lubricant from both wheel ends.
  • Page 49 Remove the Planetary Spider 9. If necessary, remove the sun gear thrust washer (14) from the end of the planetary ring gear (15). Assembly 10. Remove the planetary ring gear (15). NOTE : If only the planetary pinions (9) are removed for inspection without removing the pinion shaft (7), 11.
  • Page 50 Remove the Spindle and Brake Assemble the Spindle, Brake Spider Spider and Brake WARNING WARNING To prevent serious personal injury and possible To prevent serious eye injury, always wear safe damage to components, be very careful when eye protection when you perform vehicle using lifting devices...
  • Page 51 NOTE : Refer to brake section of this manual, to install the brake camshaft, anchor pin components, brake shoes, brake springs, slack adjusters and related parts. 11. Install the air chamber to bracket mounting nuts. Tighten the nuts to 100-115 lb•ft (136-156 N•m). 12.
  • Page 52 Adjust the wheel Bearing Preload NOTE : To adjust the wheel bearing preload, the bearings must be seated and the rollers in proper alignment. WARNING Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer.
  • Page 53 9. Install the sun gear thrust washer (14). The washer tangs must engage the holes in the ring gear (15). 10. Install the planetary sun gear (13) and snap ring (12) onto the axle shaft (30). 11. Install the axle shaft and sun gear assembly (30, 13, 12).
  • Page 54 Install the Planetary Spider Assembly 1. Install the planetary spider and gearing assembly onto the wheel hub (23). For correct installation, the planetary pinions (9) must engage both the sun gear (13) and the ring gear (15) before intstallation. 2. Install the five slotted head screws (5) that attach the planetary spider (3) to the wheel hub (23).

  • Page 55: Axle For D150 & D160S-5 Truck

    Axle for D150 & D160S-5 Remove the Brake Drum Truck WARNING Removal and Disassembly - Block the wheels to prevent the vehicle from Planetary Axle moving. Support the vehicle with safety stands. Do not work under a vehicle that is supported only NOTE : Numbers in parenthesis ( ) refer to the Axle by jacks.
  • Page 56 4. Remove the wheel nuts and dual tire/rim assemblies from both wheel ends. 5. Rotate the wheel ends so the magnetic drain plug (2) in the planetary spider (8) is at the bottom. Remove the plug. Drain and discard the lubricant from both wheel ends.
  • Page 57 Remove the Planetary Spider NOTE : The sun gear thrust washer (15) may come out with the axle shaft and sun gear assembly. Assembly 10. Remove the snap ring (13) from the axle shaft 1. With a lifting device, remove the planetary spider (33) to allow for the removal of the sun gear (14) assembly (8) from the wheel hub (24) and set it on from the axle shaft.
  • Page 58 Disassemble the Brake 5. Remove the spindle (30) from the axle housing. If necessary, tap lightly on the spindle to loosen the pilot fit and to overcome the adhesion due to cured To disassemble the brake, refer to the brake section gasket material in the flange joint.
  • Page 59 Assemble the Spindle, Brake Spider and Brake WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. 2. Apply a 0.125 inch (3.18 mm) diameter continuous bead of silicone gasket material (Three Bond 1216 or Loctite 5699) around the flange mounting face of either the axle housing or the spindle.
  • Page 60 10. Install the brake camshaft bracket clamp around the bracket tube and install the two capscrews and washers that mount the clamp to the axle housing. Tighten the capscrews to 35-50 lb•ft (47- 68 N•m). NOTE : Refer to the brake section of this manual, to install the brake camshaft, anchor pin components, brake shoes, brake springs, slack adjusters and related parts.
  • Page 61 Adjust the wheel Bearing WARNING Preload Take care when using Loctite to avoid serious personal injury. Follow the manufacturer’s NOTE : To adjust the wheel bearing preload, the instructions to prevent irritation to the eyes and bearings must be seated and the rollers in proper skin.
  • Page 62 Assemble the Planetary WARNING Spider and Gearing When you apply some silicone gasket materials, Assembly small amounts of acid vapor are present. To prevent possible serious injury, the work area NOTE : If the original planetary pinions are used, must be well-ventilated. If the silicone gasket verify that the gear bores (11) for damage.
  • Page 63 8. Mount the inner and outer wheels. Install the wheel nuts and tighten them to the specification. NOTE : This is a common lubrication axle. Add lubricant at the three locations until it runs out of the fill/level holes. 9. Add the correct axle lubricant into each wheel end through the fill/level hole in the planetary spider cover (3) at the horizontal position (3 or 9 o’clock).

  • Page 64: Brakes

    Brakes Remove Brake Shoes Disassemble Brakes Remove Wheel Components WARNING To prevent serious eye injury, always wear safe eye protection when performing maintenance or service. WARNING Do not work under a vehicle supported only by jacks. Jacks can slip or fall over and cause serious personal injury.
  • Page 65 Remove Camshaft and Slack Adjuster NOTE : Doosan recommends that you check the bushings at every reline. 3. Rotate the top shoe to release the tension on the return spring and remove the shoe. 4. Remove the bottom anchor pin (see step 2) and remove the second shoe.
  • Page 66 Inspect Parts A. Check the brake drums for cracks, severe heat checking, heat spotting, scoring, pitting and distortion. Replace drums as required. Doosan recommends that you do NOT turn or rebore brake drums because it decreases the strength and heat capacity of the drum.
  • Page 67 Assemble Brakes NOTE : To help avoid shorter lining life, Doosan recommends that you replace springs, rollers, anchor pins and cam bushings at each reline. WARNING To prevent serious eye injury, always wear safe eye protection when performing maintenance or service.
  • Page 68 Brake Slack Adjuster Position (BSAP) 4. Use a brass drift to install the anchor pin. If necessary, align the flat or groove on the pin with the holes in the spider and bushing. 5. Install the anchor pin washers. felts, seals, retainers and snap rings as required.
  • Page 69 Adjust the Brake Visual Inspection of the Brake System 1. Turn the adjusting nut of the manual slack adjusters until the linings touch the drum. Then, turn the nut in the opposite direction for one or two For safe operating conditions and longer component clicks so that the linings just clear the drum.
  • Page 70 D110/130S-5 During a major overhaul, the following parts must be D150 2-1/4 inches (57.1 mm) carefully checked and replaced with genuine Doosan D160S-5 Replacement Parts if required: NOTE : The adjusting bolt on some manual slack 1. Backing plates or spiders for distortion and loose...
  • Page 71 Brake Adjustment Inspection Maximum Stroke at Which Brake Must be Adjusted. 80 - 90 PSI (550 - 620 kPa) Air Pressure In the Air NOTE : Brake adjustment must be checked with 80 ~ Chamber. Clamptype Air Chamber. 90 psi air pressure in the brake chambers when the Chamber Stroke Length brakes are fully applied.
  • Page 72 Power Train Disassembly & Assembly...

This manual is also suitable for:

D130s-5D160s-5D100D120D150

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