Doosan D20S-3, D25S-3, D30S-3, D32S-3, D25S-3(B3.3) User Manual

SB2102E01

J a n . 2 0 0 4

Specifications

Systems Operation

Testing & Adjusting

Lift Trucks Power Train D20S-3, D25S-3, D30S-3, D32S-3

D20S-3(B3.3), D25S-3(B3.3), D30S-3(B3.3), D32S-3(B3.3), D33S-3(B3.3)

G20S-3, G25S-3, G30S-3 GC20S-3, GC25S-3, GC30S-3 G20E-3, G25E-3, G30E-3, G32E-3

GC20E-3, GC25E-3, GC30E-3, GC32E-3 G20P-3, G25P-3, G30P-3, G32P-3 GC20P-3, GC25P-3, GC30P-3, GC32P-3

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary

training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication, maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
p re c au tion s are listed in the	“Sa fety ” section of the	o wner/ope	ration/maintenance pu	b lication	.

Specific safety warnings for all these publications are provided in the description of operations where hazards exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this publication and on the product labels are identified by the following symbol .

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, 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.

DAEWOO cannot anticipate every 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 specifically recommended by DAEWOO 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.

The information, specifications, and illustration in	this publication are	on	the basis of information available at the
time it was written. The specifications, torques,	pressures, measurements,		adjustments, illustrations, and other
items can change at any time. These changes can affect the service given		to	the product. Obtain the complete

and most current information before starting any job. DAEWOO dealers have the most current information available.

1

Index
Specifications
Drive Axle Mounting Group.......................................	14
Drive Tire Installation ................................................	12
Drive Wheel Installation ............................................	13
Final Drives And Wheels...........................................	11
Forward / Reverse Clutch Elements ...........................	6
Forward And Reverse Control Group .........................	5
Tightening Torques .....................................................	9
Torque Converter........................................................	5
Transmission Solenoid ...............................................	5
Valve Block Elements .................................................	7
Valve Spring in Transmission Bearing Plate ...............	8
Systems Operation
General Information ..................................................	15
Transmission and Drive Axle ....................................	16
Basic Control Scheme...........................................	34
Drive Axle ..............................................................	21
Hydraulic System ..................................................	24
Torque Converter ..................................................	16
Transmission.........................................................	17
Transmission Hydraulic System............................	25
Testing And Adjusting
Troubleshooting ........................................................	38
Check List During Operation .................................	39
Check List From Operation Noises .......................	40
Check List From Pressure Tests ...........................	41
Visual Checks .......................................................	38
Transmission and Drive Axle Tests And Adjustments
..................................................................................	44
Adjustment of Crown Wheel..................................	58
Adjustment of Wheel Bearings..............................	60
Adjustments on Drive Axle and Transmission .......	55
Converter Stall Test ...............................................	46
Electric Control System Tests ...............................	50
Inching Pedal Adjustment......................................	53
Installation of Pinion ..............................................	57
Maintenance Transmission and Drive Axle ...........	48
Transmission Pressure Tests ................................	44

Power Train

3

Index

	Specifications	Forward And Reverse Control
		Group
	Torque Converter

(1) Torque for six bolts that hold torque converter drive plate to the flywheel

…………………………………...45 ± 7 N·m (33 ±5 lb·ft)

(1)Torque for screws (four) that hold clamp to hand control switch………..3.4 to 3.9 N·m (30 to 35 lb·in)

(2)Torque for bolts (two) that hold clamp to steering column……………….2.8 to 3.4 N·m (25 to 30 lb·in)

Apply a bead of LOCTITE NO.242 Sealant to inner radius of the clamp, prior to assembly.

Transmission Solenoid

Valve block elements located on top of transmission housing…………………………………9.7 to 10.3 ohms

For additional solenoid and valve group specifications see section “Valve block elements”

Power Train

5

Specifications

Forward / Reverse Clutch

Elements

C	1.4 minimum

B

A

Snap ring

a) Outer clutch Disc

b) Inner clutch Plate

c) Piston return spring

Length under test force……………...29 mm (1.14 in) Test force………………..970.9 ±50 N (218.4 ± 11 lb) Free length after test(nominal) ..…56.6 mm (2.23 in) Outside diameter…………………..…95 mm (3.74 in)

d)Clearance between piston and pressure disc (disc pack pushed against snap ring, piston fully retracted in gear)………………..1.4 mm (0.0551 in)

Power Train

6

Specifications

Valve Block Elements (On top of transmission)

Tighten to 50±7 N·m (37±5 Ib·ft)
Tighten to 0.6 N·m (0.44 Ib·ft) min
Tighten to 25±4 N·m (18.5±3 Ib·ft)	SECTION A-A
Tighten to 5±1 N·m (3.7±1 Ib·ft)

Tighten to 5.5±1.5 N·m (4±1 Ib·ft)

A	C	Tighten to 50±5 N·m (37±3.7 Ib·ft)
	D,E
Tighten to 50±7 N·m	B
(37±5 Ib·ft)

Tighten to 50±7 N·m (37±5 Ib·ft)

A) Spring

Length under test force……..…...22.5 mm (0.89 in) Test force………………,,,….42 ± 3.4 N (9.4±0.8 lb) Free length after test(nominal)...34.65 mm (1.36 in) Outside diameter…………………...13 mm (0.51 in)

B) Spring(Inner)

Length under test force……….….26.6 mm (1.05 in) Test force……………….….37.8 ± 3.0 N (8.5±0.7 lb) Free length after test(nominal)….48.2 mm (1.90 in) Outside diameter………………….10.8 mm (0.43 in)

C) Spring(outer)

Length under test force…………..26.6 mm (1.05 in) Test force………………….75.6 ± 6.0N (17.0±1.3 lb) Free length after test(nominal)….52.6 mm (2.07 in) Outside diameter………………..15.24 mm (0.60 in)

D) Spring(outer)

Length under test force…………22.22 mm (0.87 in) Test force…………………...29 to 34 N (6.5 to 7.6 lb) Free length after test(nominal)….31.7 mm (1.25 in) Outside diameter………………...11.91 mm (0.47 in)

E)Spring(Inner)

Length under test force………..…20.0 mm (0.79 in) Test force……………...3.34 ± 0.27 N (0.75±0.06 lb) Free length after test(nominal)...55.93 mm (2.20 in) Outside diameter………………..7.75 mm (0.305 in)

Power Train

7

Specifications

Valve Spring in Transmission Bearing Plate

A Tighten to 45 N·m (33.2 Ib·ft) 2-Springs

Converter Inlet Valve

Tighten to 45 N·m (33.2 Ib·ft) Converter Outlet Valve

A) Spring

Length under test force…………….30 mm (1.18 in)

Test force…………….......18.1 ± 1.8 N (4.07±0.4 lb)

Free length after test(nominal)...43.25 mm (1.70 in)

Outside diameter…………………10.7 mm (0.42 in)

Power Train

8

Specifications

Train Power

9

Specifications

Housing Bolt 55 Nm (4.6 Ibft)

Bearing Shims

Axle Lube Pump Bolt 12 Nm (8.9 Ibft)

PTO Pump Bolt 30 Nm (22.1 Ibft)

U-joint Bolt 70 Nm (51.7 Ibft)

Bearing Shims

See Instructions

Housing Bolt 55 N m	Plug 50 N m (36.9 Ib ft)
(40.6 Ib ft)

Bolt 20 Nm (14.8 Ibft)

Bearing Plate

Bolt 55 Nm (40.6 Ibft)

Pump Housing

Bolt 32 Nm (23.6 Ibft)

Flexplate Bolt 55 Nm (40.6 Ibft)

Bearing Shims

See Instructions

Bolt 40 Nm (29.5 Ibft)

Torques Tightening

Train Power

Nut 50 Nm (36.9 Ibft) (See Instructions)

10

Bolt 285 Nm (210.3 Ibft)

Apply Loctite 242 to thread

Specifications

Spacer and Shims

(See Instructions)

Shims

(See Instructions)

Nut 150 Nm (110.7 Ibft)

Apply Loctite 242 to thread and face

Bolt 115 Nm (84.9 Ibft)

Apply Loctite 242 to thread

	Adjust to	Bolt 80+8 N m (59.0+5.9 Ib ft)
		(Slightly Oiled)
	19.6 N m (14.5 Ib ft) drag
	(See Instructions)
	Grease Bearing	Bolt 115 N m (84.9 Ib ft)	Bolt 28 N m (20.7 Ib ft)
	With Molycote BR2	Apply Loctite 242 to thread
			Apply Loctite 242 to thread

Torques Tightening

Final Drives And Wheels

GC Model Trucks

1

2

3

4 5

Oil Cooled Disc Brake Type

(1)Apply LOCTITE NO.242 Thread Lock to threads of spindle bolts.

Torque for bolts that hold spindle to drive axle housing……………..115 ± 14 N∙m (85 ± 10 lb∙ft)

(2)Torque for wheel mounting bolts…270 ± 25 N∙m

………………………………………(200 ± 20 lb∙ft)

(3)Wheel bearing adjustment :

(a)Tighten wheel bearing nut to 135 N∙m (100lb∙ft) while the wheel is turned in both directions.

(b)Loosen the nut completely. Tighten the nut again to 50 ± 5 N∙m (37 ± 4 lb∙ft).

(c)Bend a tab of the lockwasher into a groove of the wheel bearing nut.

(4)Torque for bolts that hold cover to axle housing

……………………………55 ± 10 N∙m (40 ± 7 lb∙ft)

(5)Apply Loctite No.515 Sealant to the axle flange and cover on the contact area.

D,G Model Trucks

Dual Drive wheels shown

1

2

3

4

5 6

Oil Cooled Disc Brake Type

(1)Apply LOCTITE NO.242 Thread Lock to threads of spindle bolts.

Torque for bolts that hold spindle to drive axle housing………………..115 ± 14 N∙m (85 ± 10 lb∙ft)

(2)Use a crisscross procedure to tighten nuts.

(a)Torque for single drive wheel mounting. nuts………...........644 ± 34 N∙m (470 ± 25 lb∙ft)

(b)Torque for inner and outer dual drive wheel mounting nuts…………………….644 ± 34 N∙m

(470 ± 25 lb∙ft)

(3)Torque for bolts that hold adapter assembly to hub………………...285 ± 13 N∙m (210 ± 10 lb∙ft)

(4)Wheel bearing adjustment :

(a)Tighten wheel bearing nut to 135 N∙m(100 lb∙ft) while the wheel is turned in both directions

(b)Loosen the nut completely. Tighten the nut again to 50 ± 5 N∙m (37 ± 4 lb∙ft).

(c)Bend a tab of the lockwasher into a groove of the wheel bearing nut.

(5)Torque for bolts that hold cover to axle housing

………………..…………..55 ± 10 N∙m (40 ± 7 lb∙ft).

(6)Apply Loctite No.515 Sealant to the axle flange or spacer and cover on the contact area.

Power Train

11

Specifications

Drive Tire Installation

GC20, GC25 Models

GC30, GC32 Models-Narrow Axle

Y

GC30, GC32 Models-Wide Axle

WARNING

The drive tire must be installed as shown below. Failure to do so will decrease the stability of the truck, and can cause injury to the operator.

GC20, GC25 Models

Install the tire so that the edge of the tire is even with the outside edge of the wheel.

GC30, GC32 Models

Narrow Axle :

Install the tire so there is distance (X) between the edge of the tire and the inside edge of the wheel.

Distance(X) is……………38.2 ± 0.8 mm (1.50 ± .03 in)

Wide Axle :

Install the tire so there is distance (Y) between the edge of the tire and the outside edge of the wheel.

Distance(Y) is....................	25.0 ± 0.8 mm (.98 ± .03 in)
.

Power Train

12

Specifications

Drive Wheel Installation

D,G Model Trucks

GC Model Trucks

1

1

(1)Tighten wheel mounting bolts to a torque of

……………………….270 ± 25 N∙m (200 ± 20 lb∙ft)

(1)Tighten wheel mounting bolts to a torque of

……………………….644 ± 34 N∙m (470 ± 25 lb∙ft) Use a crisscross procedure to tighten nuts.

Power Train

13

Specifications

Drive Axle Mounting Group

1	Special shoulder Bolt

Chassis

Standard Bolt

Drive

Axle

Housing

2

(1)Torque for two nuts that hold the axle to the chassis……………..…488 ± 27 N∙m (360 ± 20 lb∙ft)

(2)Torque for two nuts that hold the axle to the chassis………...…..….488 ± 27 N∙m (360 ± 20 lb∙ft)

Power Train

14

Specifications

Systems Operation

General Information

2

3

4

1

Power Flow

(1) Drive axle. (2) U-joint. (3) Transmission. (4) Engine.

The basic components of the power train are engine (4), Transmission (3), U-Joint(2), Drive axle(1) and the final drives and wheels.

Two axle shafts connect the differential to two final drives. The drive wheels are mounted to the final drives.

Power from the engine goes through the flywheel into the torque converter. Power then flows through a transmission (3) and U-joint(2) to yoke of

drive axle(1).

The transmission has two hydraulically operated clutch packs that are spring released.

The transmission has one speed in forward and one speed in reverse.

Power from yoke of drive axle is sent through a spiral bevel gear set to the differential.

The differential sends power out through the axles to the final drives and wheels.

Power Train

15

Systems Operation

Transmission and Drive Axle

Torque Converter

4

2

6

5

1

3

Torque converter

(1) Turbine. (2) Stator. (3) Impeller. (4) Housing.

(5) Stator support. (6) Stator clutch.

There is no direct mechanical connection between engine and the transmission. Power from the engine is transferred through the torque converter, which hydraulically connects the engine to the transmission.

Transmission drive train oil is used to turn the turbine and transmission input shaft.

When the lift truck works against a load, the torque converter can multiply the torque from the engine and send a higher torque to the transmission.

The torque converter has four main parts : housing (4), impeller(pump) (3), turbine(1) and stator(2). The housing is connected to the engine flywheel through a flexplate. Impeller (3) and housing (4) are welded together and turn with the engine flywheel at engine speed and in the direction of engine rotation. Turbine

(1) turns the transmission input shaft. Stator (2) is installed stationary on stator support (5) by a freewheel clutch that allows one way rotation of the stator.

The hub, which is part of impeller (3), fits into the transission oil pump. The turning impeller (3) rotates the pump to supply oil for the operation of the torque converter and transmission

When the engine is turning, oil flows through the converter to lubricate and cool it. With the transmission in neutral, the impeller, turbine, stator and oil are all turning together in a direct fluid coupling. The turbine/impeller speed ratio is 1/1.

Once a direction is selected the direct fluid coupling no longer exists, the turbine/impeller speed ratio changes (the turbine will be turning slower than the impeller). When this happens the impeller outlet pressure to turbine inlet pressure changes. This causes the oil flow in the torus (fluid path containing the impeller, turbine and stator) to gain momentum.

As impeller (3) turns, it increases the energy state of the oil and directs the oil to the outside diameter of converter housing (4). Oil leaving impeller (3) is directed to turbine (1) where much of the oil? energy is absorbed by turning the turbine. The pressure and flow change in the torus becomes torque and speed at the turbine and transmission input shaft.

Oil follows the turbine blades inward toward the center of the converter. When the turbine/impeller speed ratio is less than .85/1, oil is directed against the concave side of stator (2) with enough force to stop its one way rotation and lock the freewheel clutch.

Most of the energy from the oil that strikes the turbine is used to turn the turbine, but some energy is left over. Torque multiplication comes about because the locked stator (2) directs this left over oil back to impeller (3) in the same direction as the impeller rotation. This energy force of the oil increases the torque on the turbine and transmission input shaft. During operation, this cycle is repeated over and over.

Without the stator, oil leaving the turbine is travelling in a direction that is against impeller rotation. Torque multiplication is only possible because of the stator.

Power Train

16

Systems Operation

Transmission

		11
3	9A	2
		10	4
		1

9

16

5A

6

14

5

15

14A

		8	7	13
					12
(1) TC Housing. (2) TM Bearing Plate.		(3) TM Housing.			(4) Torque Converter.	(5) Input Shaft. (5A)Input Shaft Gear.
(6) Oil Pump. (7) Forward Gear. (8)		Forward Clutch.			(9) Reverse Shaft. (9A) Reverse Shaft Gear. (10) Reverse Clutch. (11)
Reverse gear. (12) Output gear. (13) U-joint.			(14) Quill Shaft. (14A) Coupling.			(15) PTO Pump. (16) Axle Lubrication Pump.

The Transmission consists of 3 sections:

a)TC housing (1) which contains torque converter (4) and the oil pump (6) and its housing. Tangs on the TC neck engage in and drive the pump.

b)Bearing plate (2) which contains the rear bearings of input, reverse shaft and output gear and the oil supply channels. The oil channels are sealed by the front TC housing wall.

c)Transmission housing (3) containing input shaft (5), forward clutch (8), forward gear (7), reverse shaft (9), reverse clutch (10), reverse gear (11), output

gear (12) and parking brake. The input shaft engages in and is driven by the TC turbine hub spline and rotates in same direction as the engine. It carries an input shaft gear (5A) which is in mesh and drives the reverse shaft gear (9A), the forward clutch (8) and the forward gear (7),

which is in mesh and drives the output gear, when the forward clutch (8) is closed.

The reverse shaft (9) carries the reverse shaft gear (9A), the reverse clutch (10) and the reverse gear (11) which is in mesh and drives the output gear (12) when the reverse clutch (10) is selected.

The quill shaft (14) is splined to the torque converter and therefore rotates with engine speed and direction. A coupling (14A) connects the PTO pump (15) to the quill shaft (14).

The axle lubrication (16) pump engages in and is driven by the reverse shaft. It always operates when the engine rotates, but rotating speed varies with torgue converter output.

Power Train

17

Systems Operation

Transmission Power Flow Forward :

With the transmission control in forward, which will pressurize the forward clutch (8), power will flow from the engine through the torque converter to drive the oil pump (6) and the input shaft (5), also the quill shaft (14). Since the forward clutch (8) locks the forward gear (7) to the input shaft, the power flows through the forward clutch (8), the forward gear (7) to output gear

(12)which is in mesh with the forward gear. The u-joint

(13)which is splined to the output gear will transmit power to the axle.

Power Train

18

Systems Operation