How it Works
Doosan
Loading...
D110S-5 with OCDB

Doosan D110S-5 with OCDB, D130S-5 with OCDB, D160S-5 with OCDB Disassembly/assembly

Vehicle System
SB4376E01 Aug.2012
Disassembly & Assembly
D110S-5 with OCDB D130S-5 with OCDB D160S-5 with OCDB
Important Safety Information
Most accidents involving pr oduct operation, maintenance and repair ar e caused by failure to observe basic safety rules or precautions. An ac cident can often be avoided by recogniz ing potent ially hazardous sit uations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perf orm these functions properly.
Read and understand all safety precau tions and warni ngs before operati ng or perfo rming lubrication , maintenance and repair on this product.
Basic safety pr ec autions are listed in the “Safety” section of the Ser v ic e or Technic al M anual. Additional safet y precautions are list ed in the “Safety” section of t he owner/oper ation/maintenance publication. Specific safet y warnings for all these public ations ar e provided in t he descript ion of oper ations wher e hazard s exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If these hazard warnings ar e not heeded, bodily injury or death could occur to you or other persons. Warnings in this publication and on the product labels are ident ified by the following sym bol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in in jury or death.
Do not operate or perfo rm any lubrication, maint enance or repair on this produ ct, until you have read and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
DOOSAN cannot anticipate ev ery possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not s pecifically recommended by DO OSAN is used, you must satisfy yourself t hat it is safe for you and others. You should also ens ure that the product will not be damaged or made unsafe by the operation, lubricat ion, maintenance or repair pr oc edur es y ou c hoos e.
The information, specifications , and illustrat ions in this publication are on t he basis of inf ormation available at the time it was written. T he specifications, tor ques, pressures, measurement s, adjustments, illustrat ions, and other items can c hange at any time. These changes can aff ect the service given to the produc t. Obtain the complete and most current information before starting any job. DOOSAN dealers have the most current information available.
INDEX
Forks ........................................................ 5
Remove & Install Forks ..................................... 5
Carriage ................................................... 6
Remove & Install Carriage ................................. 6
Carriage Rollers ...................................... 7
Remove & Install Carriage Rollers ..................... 7
Disassemble & Assem ble Car r iage Roller s ........ 7
Disassemble & Assem ble Car r iage .................... 8
Mast ......................................................... 9
Remove Mast .................................................... 9
Install Mast ...................................................... 10
STD Mast ........................................................ 11
Disass embly ................................................ 11
Assembl y ........................................................ 1 4
FFT Mast......................................................... 18
Lift Cylinder ........................................... 20
Removal & Installation ..................................... 20
Disassembly .................................................... 22
Assembl y ........................................................ 2 4
Tilt Cylinder ........................................... 25
Removal & Installation ..................................... 25
Disassembly & Assembly ................................ 26
Brake Assembly .................................... 29
Removal & Installation ..................................... 29
Remote Control Valve .......................... 31
Replacing the parts ......................................... 31
Attachment Carriage ............................ 33
Lift Cylinder and Mast .......................... 33
Hydraulic Pump .................................... 35
Removal & Installation ..................................... 35
Start-up Inst ructions & Recommendations ....... 36
Rotation & Ports Indication ........................... 36
Start-up : ...................................................... 36
Removal of Air in Pump – Motor line ................ 36
Pump & Cartridge Breakdown Dr awing ............ 37
Disassembly .................................................... 38
Reasse mbly .................................................... 43
Seal Driver ...................................................... 48
Dimension of Protective Cone ......................... 48
Hydraulic Oil Filter ................................ 49
Removal & Installation ..................................... 49
Disassembly & Assembly ................................ 49
Universal Joint ......................................50
Removal & Installation .....................................50
Disassembly & Assembly .................................51
Steering Wheel & Gear .........................52
Steering Wheel ................................................52
Removed & Disassembly of Steering Gear.......52
Assembly of Steering Gear ..............................54
Steer Axle ..............................................58
Removal & Installation .....................................58
Steering Cylinder ..................................60
Removal & Installation .....................................60
Disassembly & Assembly .................................62
Steering Knuckle, Kingpin And Bearings
................................................................64
Removal & Installation .....................................64
Steer Tire And Rim ................................67
Removal & Installation .....................................67
Removal of Wheel Bear ing ..............................67
Installation of Wheel Bearing ............................68
Drive Tire And Rim ................................69
Removal & Installation .....................................69
Counterweight .......................................70
Removal of Air.......................................71
Pump – Motor line ............................................71
After changing main pump ...............................71
Air in Brake system ..........................................72
Removal of the High Pres sure in accumulator ..72
Emergency Lowering .......................................73
Removal and installation of Engine and
Transmi ssion ...................................................74
Forks
Remove & Install Forks
1. Pull out pin assembly ( 1) from the fork.
2. Rem ov e two bolts, washers (2) and plate ( 3) .
3. Support the fork with strap and hoist. Remove
shaft (4). Remov e str ap and hois t 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 carriage until for k is s epar ated from the carriage. Drive the truck at backwar d dir ec tion.
5. Repeat steps 1 through 4 f or the ot her fork.
6. Install the fork s in the rev erse order of removal.
Carriage
Remove & Install Carriage
Start By :
a. Remove forks.
1. Com pletely lower carriage and inner m as t.
2. Attach a hoist t o the car r iage as shown.
3. Lift the car riage wit h the hoist unt il the chains and
hoses hang loosely.
4. Put identification marks on sideshift cylinder hoses if equipped. Disconnec t two hoses.
5. Rem ov e the cotter pin and pin (2) f r om both of t he lift chains.
6. Start the engine. Raise the mast until the inner mast clears the car r iage.
7. Remove the carriage. The weight of the carriage is 936 kg (2063 lb).
NOTE : The following steps are for installation of the carriage. See the topic ent itled Carriage Adjustment in the Testing and Adjusting Manual bef ore inst alling the carriage on the m ast.
8. Attach a hoist t o the car r iage as shown.
9. Start the engine. Rais e the mast until t he carriage
will go under the inner mast .
10. Move the carriage in position under the mast.
11. Completely lower the mast over the carriage
making sure the roller s ar e pr oper ly aligned inside the inner mast.
12. Connect two hoses. If necessary, rais e the carriage slightly wit h the hoist.
13. Pull the chains into position on the carr iage. Install pin (2) and t he cotter pin in both of the lift chains.
14. Make an adjust m ent to the lift chains. See the topic entitled Chain Adjus tments in the Testing and Adjusting Manual.
End By : a. Install forks.
Carriage Rollers
Remove & Install Carriage Rollers
Start By :
a. Remove car r iage.
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
carriage rollers.
3. P ut the load roller in position on the carriage.
4. Install the snap ring that holds the roller in place.
End By :
a. Install carriage.
Disassemble & Assemble Carriage Rollers
Tools Needed A B
Bearing Cup Puller Att achment Puller Assembly Ratchet Box Wrench Bearing Installer
Start By : a. Remove car r iage r oller s ( load) .
1 1 1
1
1. Rem ov e s nap ring (1) from the roller.
2. Remove bearing (2) from the roller using the tool
group (A).
NOTE : The following steps are for the as sembly of the carriage rollers .
3. Put (pack) clean grease in the bearings for the
load roller.
4. Install bearing (2) in the roller using tool ( B ).
5. Install snap ring ( 1) in the roller. End By :
a. Install carriage r oller s ( load)
Disassemble & Assemble Carriage
Start By :
a. Remove car r iage
Tools Needed A
Bearing Cup Puller Att achment 1
1. Remove snap ring (1) with tool (A).
2. Rem ov e roller (2) from the pin of the c arriage.
3. Remove bolts (4), washers, roller and bracket
assembly (3) and shims (5) from carriage assembly.
4. Disassemble the roller and bracket assembly (3)
as follows:
a. Remove grease fitting (6). b. Remove bolt (7) and washer that hold shaft (8)
in bracket.
NOTE : When assembly, apply Loctite No.242 to bolt thread.
c. Tap the shaft ( 8) and r emove shaft from
bracket.
d. Remove spacers (9) and roller (10). e. Remove bushings (11) from r oller ( 10) .
Replace the bushings with new ones if worn or damaged.
NOTE : Assemble carriage in the reverse order of disassembly.
End By :
a. Install carriage. b. Make an adjustment to the carriage (see Carriage
Adjustment in Test ing and Adjusting).
Mast
Remove Mast
Start By :
a. Remove carriage.
1. Fully lower mast.
2. Fasten a hoist to the mast as shown.
3. Tilt the mast forward. Disconnect hydraulic lines
(1).
4. B end bac k the tab on clip (4).
5. Remove bolt (3), clip (4) and block (2).
WARNING
Tilt cylinders can drop when pin (6) is removed. To avoid component damage or personal injury, support tilt cylinder while removing pin (6).
6. Remove retaining bolts (5). Remove pin (6).
7. Repeat Steps 4, 5 and 6 for the other side of t he
mast.
8. Start the engine. O perate the contr ol lever for the
tilt cylinders until the rods are fully retrac ted.
9. Remove the mast from the frame of the vehicle.
The weight of the mast is approximately 2600 to 4400 kg (5732 to 9700 lb).
Install Mast
1. Install the mast on the frame of the vehicle. The
weight of the mast is appr oximately 2600 t o 4400 kg (5732 to 9700 lb).
2. Start the engine. O perate the contr ol lever for the tilt cylinders until the holes in the cylinder rods are aligned with the holes in the mas t.
3. Install two pins (6). Inst all bolts (5) and retainers to hold both pins in place.
4. Inst all bolts (3), clip (4) and bloc k ( 2) on eac h s ide. Torque bolts (3) to 800 ± 100 N•m (590 ± 74 lb•ft).
5. Bend back the tabs on clips (4) against the bolt heads.
6. Connect hydr anlic lines ( 1) . NOTE : If lift c ylinders wer e remov ed from the mas t,
adjust both lift chains to equal tension. Run the mast to full lift. If mast does not kick to either side no shims are required. If mast does kick to one side disconnect cylinder from support assembly on that side. Add shims, reassemble and repeat. Repeat process until “kic king” is corr ected. Do not exceed 3 mm (.12 in) of shims.
End By : a. Install brack et assembly carriage.
Vehicle System Disassembly & Assembly 10
STD Mast
Disassembly
Start By :
a. Remove mast.
1. Rem ov e hos e (1) and bracket (2).
2. Remove hose (3), flow protector (4) and flow
regulating and bracket assembly (5) from outer mast channel.
3. Bend back the plate (7) support ing nut (6) not to be loosened. Remove nut (6), plate (7), spacers (8), pad-rubber (9) and clamp assembly(10) if they were installed.
4. Remove grease pipe if it was inst alled.
5. Rem ov e bolt (12) and washers.
6. Remove bolts (13) , washers and nuts.
7. A ttach hoist to lift cylinder (14).
8. Remove lift cy linder (14). The weight of the
cylinder is 171 to 400 kg (377 to 881 lb) . Mark for identification and rem ove the shims at top of cylinder (14).
NOTE : At inst allation, adjust both lift chains with t he same tension. Run the mast to full lift. If mas t does not kick to either side, no shimming is required. If mast does kick to one side, disc onnect cylinder from support assembly on that side. Add shims to reassemble Repeat this process until “kicking” is corrected.
Vehicle System Disassembly & Assembly 11
9. Remove pads (15) and shims from the outer mast channel.
10. Remove the s nap- r ing from the outer mast pin.
Remove roller assemblies ( 16) from the outer mast channel.
NOTE : Place identification marks on all roller assemblies (16) t o as s ur e pr oper installation.
11. Remove bolts (17), washers, roller and bracket
assembly (18) and shims from the outer mast channel.
NOTE : Mark and separate the shims and roller and bracket assemblies (18) r emoved f rom each s ide for identification at as s em bly .
12. Remove s nap-ring (19) from the inner m ast pin. Remove roller assemblies (20) from the inner mast channel.
NOTE : Place identification marks on all roller assemblies (20) t o as s ur e pr oper installation.
13. Remove bolts (21), washers, roller and bracket assembly (22) and shims from the inner mast channel.
14. Remove c hains from the outer mast.
15. Repeat st eps 10 through 13 for the other side.
16. Fas ten a hoist to outer mast (23). Use a lift truck
to separate inner m as t (24) from outer mast (23).
The weight of outer mast (23) is about 1230kg
(2771lb) and The weight of inner mast (24) is about 910kg (2006lb).
Vehicle System Disassembly & Assembly 12
17. Remove s nap- r ing ( 24) , bearing (25) from roller (26) if needed.
18. Remove bolt ( 27) , washer and grease fitting. T ap the shaft and remove s haft ( 28) , spac er s (30), and roller (29) from the brac k et if needed.
19. Check the c ondition of bushing (30) in the roller (29). Replace the bushing (30) with new one if worn or damaged.
20. Support crosshead assembly ( 32) with a hois t and remove eight bolts, washers (31) and crosshead assembly (32) from the inner mast channel.
21. Remove r etaining bolts, washers ( 33) and pins (34) and then remove c hain s heav es ( 35).
22. Remove snap-r ing ( 37) and bear ing (38) from the wheel if needed.
Vehicle System Disassembly & Assembly 13
Assembly
Tools Needed A B C
Vernier Calipers 1 Inside Vernier Calipers 1 Mast Gauge 1
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.
3. Install bearing (38) and snap ring (37) into the wheel if they were rem ov ed.
4. Inst all chain sheav es (35), pins (34), washer s and retaining bolts (33) that hold pins (34) to the crosshead assembly.
5. Put crosshead assembly (32) in position and install washers and bolts (31). Adjust crosshead assembly (32) of which distance difference (X) between left hand and right hand should be within
1.5mm(.06 in) from side of the inner beam. Tighten bolts.
6. When crosshead assembly (32) is assembled, distance difference (Y) between left hand and right hand should be wit hin 1.5 mm (.06 in) f rom front of the inner beam .
7. Install new bushes (30) into the roller.
Vehicle System Disassembly & Assembly 14
8. Install the shaft, spacers and roller (29) to the bracket. Install bolt (27) and washer using Loctit e No.242. Install grease fitting (28) to the shaft. Be careful for assembling direc tion.
Typical Example
9. To shim the inner m ast (lower) side roller, move gauge (C) up and down inside outer mas t channel (8) to find the narrowest point across the outer mast channels in track wher e the side roller t ravel. Measure the channel lap which is the distance between the outer rail upper face and inner rail lower face. Record this measurement. The channel lap is to be shown in the below t able.
MFH 3.0~4.5 M 5.0~6.0 M
CHANNEL
LAP
1115 mm 1315 mm
10. Inst all the inner mast channel side roller and bracket assemblies (22) without shims on the inner mast.
11. Measure t he dis tance between inner mast side rollers with tool ( A ) . Add s him s between one of side rollers to be 0.2~0.8 mm (.008~.031 in) clearance.
12. Divide t he s him s into two groups to have the same thickness and ins tall them on each side of the inner channel behind side roll er and bracket assemblies (22).
13. To shim outer mast (upper) side roller(18) , measure outside of the inner m as t channel ( 24) to find the widest point ac r os s t he inner m ast channels in the track where side roller (18) travel using tool (A). Rec ord this measurement.
14. Ins tall the outer mast channel side roller and bracket assemblies (18) without shims on the outer mast.
15. Measure t he dis tance between outer mast side rollers (18) with tool (B). Add shims between one of side rollers t o be 0.2~ 0.8 mm (.008~.031 in) clearance.
Vehicle System Disassembly & Assembly 15
NOTE : Assemble after spray to anti-seizing lubricant, Molybdenum disulfide type between bearing and roller.
16. Ass em ble the bearings and snap rings into the rollers if they were removed. Install roller assemblies (20) on t he inner m as t pin. Install snap rings (19).
17. Ins tall roller assemblies (16) on the outer mast pin. Install t he snap rings.
18. Use a hoist and nylon strap to install inner m ast (24) into outer m ast c hannel ( 23) .
The weight of outer mast ( 23) is about 1230k g
(2771lb) and The weight of inner m as t (24) is about 910kg (2006lb).
19. Place the shims between wear pads ( 15) and the inner mast. Clearance (X) between outer roller (16) and inner mast flange is to be 0.0 to 1.0 mm (.0 to .04 in).
20. Slide the mas t completely together.
21. Inst all the chains on each side of the outer mast.
22. Fas ten a hoist and nylon str ap to lift cylinder ( 14)
and put lift cylinder (14) and shims in position. Install bolts ( 13), washers and nut.
23. Ins tall bolts (12) and washers on the inner m ast. Apply the Loctit e No.242 t o thread of bolts (12).
Vehicle System Disassembly & Assembly 16
24. Ins tall clamp assembly (10), pad- r ubber (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 assem bly ( 10).
25. Ins tall grease pipe if it was removed.
26. Install t he flow regulating and bracket assembly
(5), flow protector (4) and hose (3).
27. Ins tall bracket (2) and hose (1).
End By : a. Install mast.
Vehicle System Disassembly & Assembly 17
FFT Mast
NOTE: Since many things f or 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 cy linder b) Remove hinge pin (2) c) Remove mast from chassis
Tilt
Shaft
Cover
Chain anchor
2. Rem ov e fork & carriage
( How to same the STD mast) a) Remove fork(1) - Remove cover & shaf t b) Remove carriage(2) - Rem ov e c ar riage chain
anchor
Vehicle System Disassembly & Assembly
18
3. Rem ov e hy draulic line. a) Remove attachment line(1)
- Remove bolt & fitting
- Close the port with plug
b) Remove lift line( 2)
- Remove clamp & fitting
- Close the port with plug
4. Rem ov e c hain & c rosshead. a) Remove chain anchor bolt ( 1) - Rem ov e pin
b) Remove chain(2) c) Remove chain sheave - Remove pin(3) d) Remove crosshead( 4) - Remove bolt
clamp
Bolt(pin)
5. Remove cylinder
a) Remove primary cylinder
- Remove clamp(1)
- Remove cylinder f itt ing bolt
b) Remove secondary c y linder ( 2)
- Remove cylinder f itt ing bolt
Side Roller As
Mast Roller As
Vehicle System Index 19
6. Rem ov e bearing & mast as a) Remove side roller bearing ( 1)
b) Remove mast roller bearing ( 2)
End by: a. Install car r iage, raise the inner mast and ins er t t he carriage from bott om of inner mast.
Lift Cylinder
Removal & Installation
1. Start the engine and l ift the inner mast. Put blocks
under the inner mast as shown and lower the weight on the blocks. Tilt the mast forward fulling.
2. Fasten a hoist to the lif t cy linder .
3. Remove bolt (1) and was hers that hold rod (2) to
the inner mast.
4. Bend back plate (3) s upporting nut (4) not to be
loosened. Remove nut (4) , plate (3), s pacers (5), rubber pad (6) and clamp assembly (7) if they were installed.
Vehicle System Disassembly & Assembly
20
5. Move the lift control lev er to the "DOWN" position and push rod (2) into t he cylinder to get enough clearance for rem ov al.
6. Disconnect hydr aulic lines (8) and (9) from the lift cylinder.
7. Remove bolt (10) , washers and nut (11) t hat hold the bottom of the cylinder to the mast.
8. Remove the lift cylinder from the machine. The weight of the cylinder is 171 to 319 kg (377 to 703 lb).
NOTE : The following steps are for the installation of the lift cylinder.
9. Fasten a hoist to the lift cylinder and put it in position on the mast. Install t he washers, nut (11) and bolt (10). Tighten nut (11) to a torque of 55~80 N∙m (40~60 lb∙ft).
10. Connect hy dr aulic lines ( 8) and ( 9) to the lift
cylinder.
Vehicle System Index 21
11. Make s ur e the bolt holes in the end of rod (2) are in alignment with the bolt holes in the inner mast plate. Start t he engine. Move rod (2) out of the cylinder until it is in c or r ec t alignment with the inner mast plate.
12. Ins tall bolt (1) and washer that hold r od ( 2) to the inner mast. Tight en bolt (1) to a torque of 55~80 N∙m (40~60 lb∙ft) with Loctite No.242.
13. Inst all c lam p as s em bly ( 7), r ubber pad (6), spacers (5), plates (4) and nut (4). Bend plates (4) that nut (4) does not loos e.
Disassembly
Start By : a. Remove lift cy linder .
Typical Example
1. P ut lift cylinder (1) in position as shown.
2. Remove head assembly ( 2) with tool.
NOTICE
Make lift cylinder ver tical by adjusting r ubber pad (6) and U-clamp assembly ( 7) .
14. Lift the mast and remove the blocks from under the inner mast. Lower the mast and stop the engine.
Vehicle System Disassembly & Assembly 22
Loading...
+ 54 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use