Doosan D40SC-5, D55C-5, D45SC-5, D50SC-5, D55SC-5 Disassembly/assembly

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Vehicle System

Disassembly & Assembly

D35S-5, D40S-5, D45S-5, D50C-5, D55C-5 D40SC-5, D45SC-5, D50SC-5, D55SC-5 G35S-5, G40S-5, G45S-5, G50C-5, G55C-5 G40SC-5, G45SC-5, G50SC-5, G55SC-5 GC35S-5, GC40S-5, GC45S-5 GC50C-5, GC55C-5

SB4267E00 May. 2007

WARNING

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 precautions are listed in the “Safety” section of the owner/operation/maintenance publication. 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.

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.

DOOSAN 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 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.

The information, specifications, and illustrations 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. DOOSAN dealers have the most current information available.

Vehicle Systems Index 3

Index

Disassembly & Assembly....................... 5

Hood (with seat) .................................................... 5

Overhead Guard.................................................... 6

Tilt Cylinders ......................................................... 7

Secondary Lift Cylinders........................................ 9

Primary Lift Cylinder ............................................ 12

Hydraulic Control Value ....................................... 15

Washing .............................................................. 17

Inspection............................................................ 17

Assembling.......................................................... 18

Relief Valve Maintenance .................................... 20

Steering Wheel .................................................... 29

Steering Unit ....................................................... 30

Brake Hydraulic Booster ...................................... 39

Tie Rods.............................................................. 43

Steering Knuckles, Kingpins, And Bearings ....... 44

Steer Axle............................................................ 45

Steering Cylinder ................................................. 46

Tires And Rims (Steer)........................................ 48

Hydraulic Control Valves...................................... 49

Hydraulic Pump ................................................... 50

General Instruction .............................................. 51

Disassembly Process .......................................... 51

Counterweight ..................................................... 56

Hydraulic Oil Filter Assembly............................... 57

Drive Axle and T/M .............................................. 57

Engine................................................................. 58

Disconnect batteries before performance of any service work.

WARNING

Vehicle Systems Disassembly & Assembly 5

Disassembly & Assembly

Hood (with seat)

Remove & Install Hood (with seat) Assembly

The hood and seat assembly can fall when nut (1) is removed from the support cylinder rod. To avoid personal injury, support the seat and hood assembly before removing nut (1).

1. Raise the hood. Support the hood with a hoist.

2. Remove nut (1) from the support cylinder.

Remove the cylinder rod from the bracket.

3. Lower the hood.

4. Remove the bolts (2) from the cover. Remove

cover.

5. Remove the washers and four bolts (3).

6. Release latch (4). Use the hoist to remove hood

and seat assembly. The hood and seat assembly weighs approximately 52 kg (115 lb).

7. Install the hood and seat assembly in the reverse order of removal.

WARNING

Vehicle Systems Disassembly & Assembly 6

Overhead Guard

Remove & Install Overhead Guard

1. Support overhead guard (1) with lifting straps and

a hoist.

2. Remove the washers, nuts, and two bolts (2).

3. Remove the washers, nuts, and two bolts (3).

4. Remove front overhead guard (1), Front overhead

guard (1) weighs approximately 30 kg (66 lb).

5. Remove the washers, nuts, and four bolts (4).

6. Remove rear Leg (5).

7. Install front overhead guard (1) and rear leg (5) in

the reverse order of removal.

Vehicle Systems Disassembly & Assembly 7

Tilt Cylinders

Remove & Install Tilt Cylinders

NOTE: The procedure for removing and installing

the tilt cylinders is the same for both cylinders.

If both tilt cylinders are removed at the same time the mast can fall. To avoid possible personal injury, make sure the mast is securely held in place or supported by a hoist before removing the tilt cylinders.

To prevent personal injury, move the control levers backward and forward to release any pressure in hydraulic system. Slowly loosen the cap of the hydraulic tank to release any pressure in the tank. Be cautious of hot hydraulic oil when any lines are disconnected in the hydraulic system.

1. Disconnect elbow (2). Remove retainer bolt (3)

and pin (1).

2. Remove retainer bolt (6) from pin (5). Remove pin (5).

3. Remove tilt cylinder (4).

4. Install the tilt cylinder in the reverse order of

removal.

WARNING

Vehicle Systems Disassembly & Assembly 8

Disassemble & Assemble Tilt Cylinders

Start By:

a. Remove tilt cylinder.

1. Remove eye (1) from the rod assembly (4).

2. Remove rod cover (2) from the cylinder tube (3)

using a spanner wrench.

NOTICE

Use extra care not to damage the highly finished surface of the cylinder rod and the bore of the clylinder tube during disassembly and assembly of the tilt cylinder.

3. Remove rod assembly (4) from the cylinder body.

4. Remove pin (5) inside hole and nut (6) from the

cylinder rod (4).

5. Remove piston (7) from the cylinder rod.

6. Remove O-ring seal (8) from the cylinder rod.

7. Remove wear ring (9) and slipper seal (10) from

the piston.

Vehicle Systems Disassembly & Assembly 9

8. Remove O-ring seal (11) and backup ring (12)

from the rod cover (2).

9. Remove wiper seal (13), backup ring (14), Upacking (15) and DU-bush (16) from the rod cover.

NOTE: Assemble the tilt cylinder in the reverse order of disassembly.

Secondary Lift Cylinders

Disassemble Secondary Lift Cylinders

Start By :

a. Remove secondary lift cylinders.

1. Put secondary lift cylinder (1) in position as shown.

2. Remove head assembly (2) with tool.

3. Remove rod (3) from the cylinder body.

Vehicle Systems Disassembly & Assembly 10

4. Remove retaining ring (4) and piston (5) from the

cylinder rod.

5. Remove O-ring seal (6) from the cylinder rod.

6. Remove O-ring seal (7), back-up ring (8) and seal

(9) from the piston.

7. Remove O-ring seal (10) from the head assembly.

8. Remove wiper seal (11), seal (12) and bush (13)

from the head assembly.

Vehicle Systems Disassembly & Assembly 11

Assemble Secondary Lift Cylinders

1. Install bush (13) and seal (12).

2. Install wiper seal (11). Install the seal with the lip

toward the outside.

3. Install O-ring seal (10) onto the head assembly.

4. Install seal (9), back-up ring (8) and O-ring seal

(7) on the piston.

5. Install O-ring seal (6) on the cylinder rod.

6. Install piston (5) and retaining ring (4) on the

cylinder rod.

7. Install cylinder rod (3) in the cylinder body.

Vehicle Systems Disassembly & Assembly 12

8. Install head assembly (2) on the cylinder rod and

tighten using tool.

End By :

a. Install secondary lift cylinders.

Primary Lift Cylinder

Remove & Install Primary Lift Cylinder

Start By :

a. Remove carriage.

1. Fasten nylon straps and hoist to the primary lift

cylinder.

2. Remove bolt (1).

3. Pull the cylinder out far enough to disconnect

hydraulic hose (2). Remove primary lift cylinder (3).

4. Install primary lift cylinder (3) in the reverse order of removal.

End By :

a. Install carriage.

WARNING

Vehicle Systems Disassembly & Assembly 13

Disassemble Primary Lift Cylinder

Start By :

a. Remove primary lift cylinder.

1. Remove bearing (1).

2. Remove rod (2) from the cylinder body.

3. Remove split rings (3) from the cylinder rod.

4. Remove O-ring seal (4) and back-up ring (5) from

the bearing.

5. Remove wiper seal (6), back-up ring (7), seal (8) and rings (9) from the bearing.

Vehicle Systems Disassembly & Assembly 14

Assemble Primary Lift Cylinder

1. Install back-up ring (7) and seal (8) in the bearing.

Install the seal with the lip toward the inside.

2. Install wiper seal (6). Install the seal with the lip toward the outside.

3. Install rings (9) in the bearing.

NOTE: Install the back-up ring with the curved side

contacting the O-ring seal.

4. Install the back-up ring (5) and O-ring seal (4) on the bearing.

5. Install split rings (3) on the cylinder.

6. Install cylinder rod (2) in the cylinder body.

7. Install bearing (1) on the cylinder body. Tighten

the bearing (1).

End By :

a. Install primary lift cylinder.

Vehicle Systems Disassembly & Assembly 15

Hydraulic Control Value

Disassembling

Keep following precautions for disassembling.

1. The main equipment has to be leveled, with all the working units grounded, engine stopped, and the actuator has to be depressurized. If disassemble the actuator while it is pressurized, high pressure oil or part may ejected out which is very dangerous.

2. Release the air pressure in tank(for pressurized tanks)

3. Clean up the surroundings of the part to be disassembled, and take care that foreign matter does not enter the valve.

4. Mark the disassembled parts or arrange them on work bench in the order of assembly in order not to confuse the order of assembling.

5. Replace all the seals(O-rings, back-up rings) which were disassembled with new seals.

6. Since the spool is matched with the valve housing by clearance control, it is not replaceable for quality. Protect it from impact of falling down.

7. Protect the sealing faces of the fitting surfaces in all sections from impact or scratch.

8. In order to minimize internal leak, the clearance of spool is kept as small as possible. Disassembling and assembling the spool may deform the spool. Therefore, full assembly replacement, when necessary, is recommended.

Refer to the attached Parts List for the dimensions and torques of the screws and plugs related with the disassembling.

Disassembling Valve Assembly

The assembling number shall be in compliance with the attached Assembly Parts List: Representative Parts No. C0240-41001.

1. Place the valve assembly on level work table, with the mounting side down. Remove the nuts(1) and (3) for the tie rod, at the end of the outlet section.

2. Slowly remove each spool section assembly in the reverse order as in the outlet section. Take care not to lose poppet, springs, or o-rings in the fitting face of each section.

3. Remove the tie rods (2) & (4) from the inlet section assembly.

Disassembling the Inlet Section Assembly

The combination number shall be in accordance with the attached Part List No. C0213-41001.

Fix the unit on the vise softly, covering the fitting face of the inlet section assembly to prevent damage.

1. Remove socket head bolt(14), remove cap(13), and remove the spool(2) in sub-assembly state from the inlet housing(1). The seal plate(5), wiper(4), and O-ring(3) on the cap(13) side have to be remain affixed to the spool(2)

【Cautions for Removing Spool 】 When removing the spool, take it out correctly to prevent dent or scratch. Dent or scratch may harm the housing hole when removing the spool, or may make it impossible to reinsert the spool, or may cause malfunction even able to be inserted. Each spool has to be marked and arranged on work bench, etc., to prevent confusion in reassembling. If assembled wrong, the actuator will fail to operate properly, which may cause serious danger.

【Fig. 2 – 1 】

Vehicle Systems Disassembly & Assembly 16

2. Hold the spool (2) on a vise by inserting rigid

wood pieces(Fig. 2-1) etc. to prevent damage on the surface. Remove the cap screw(11), disassemble spring seat(7) and spring(6), and remove wiper(4) and O-ring(3). At this time, take care that cap screw or other parts are not ejected out by the spring force.

3. Remove the screw(15) on the spool head, remove the seal plate(5), wiper(4) and O-ring(3).

4. Unscrew and remove the solenoid valve (24）, remove spring(22) and poppet(21).

5. Take off plug(18), and remove spring(17) and poppet(16).

6. Unscrew the lock nut on the shut-of valve(20). Turn the set screw by 1 or 2 turns and take it off inwardly, and take out the main body of the shutoff valve.

7. Remove the socket head bolt(40), take out the solenoid(38). Since an O-ring is mounted on the in-low part of the solenoid providing large friction force, do not apply excessive force to twist it. Remove shuttle(36) and spring(37) from inside to outside.

8. Unscrew the two relief valve assemblies(41) and remove them from the assembly. Though the two valves are identical in appearance, however, since the pressure settings for the main relief and second relief valves are different, mark the two relief valves for distinguish them.

【Cautions for Disassembling the Relief Valve】 In principle, the relief valve has to be replaced in assembly unit. Therefore, do not disassemble it except when necessary. If it is necessary to disassemble, refer to the Relief Valve Maintenance Manual. Mark each part for identification in assembling.

9. Take out plug(52), remove spring(51) and spool(50).

10. Take out plug(30) and remove spool(26) and

spring(27) in assembly state. Hold the sub-assembled spool(26) with a vise using rigid wood pieces(Fig. 2-1) to prevent damage on spool surface. Take out plug(29) and remove the check valve(28) from inside.

11. Take out plug(34) and remove spring(33) and poppet assembly(32).

Then, remove the main poppet from the poppet

assembly(32).

The poppet assembly was described as the

unload valve in the Operation Section earlier.

12. Take out the two plugs (42) and (59). These three plugs are only for open/close, without internal sub-parts. Therefore, do not disassemble them except when necessary.

13. Finally, remove the O-rings and wipers on each disassembled part.

Disassembling the Spool Section Assembly for Tilting

The combination No. shall be in accordance with the attached Part List (Part No.: C0213-41201). Fig. 2-2 is the detail drawing.

1. Take out the O-rings(12) & (18) from the fitting

surface, remove spring(11) and poppet(10).

2. Unscrew the socket head bolt(14) and take out

the cap(6). Take out the spool(2) in sub-assembled state from the valve housing(1). At this time, remove the seal plate(3), wiper(5) and O-ring(4), on the cap side, as mounted on the spool(2).

3. Loosen the screw(13) on the opposite side,

remove seal plate(3), wiper(5), and O-ring(4).

Vehicle Systems Disassembly & Assembly 17

4. Hold the spool(2) in a vise using rigid wood

pieces(Fig. 2-1) to prevent damage. Remove cap screw(8) and remove spring seat(7), spring(9), wiper(5) and O-ring(4). At this time, take care that cap screw or other parts are not ejected out by the force of the spring(9).

5. Remove spring(16) from inside the spool(2). Remove the valve(15) from the spool(2) by unscrewing the M4 screw at its end.

Disassembling the Spool Section Assembly for Attachment

The combination shall be in accordance with the attached Parts List(Part No. C0213-41202).

The disassembling of the Part No. C0213-41203 in the attached Parts List is same as this section, therefore, not described.

1. Remove O-rings(12), (18) from the fitting surface, and remove spring(11) and poppet(10).

2. Unscrew socket head bolt(15) and remove cap(6). Take out the spool(2) from the valve housing(1) in sub-assembled state. At this time, remove seal plate(3), wiper(5) and O-ring(4) on the cap side as mounted on the spool.

3. Remove the screw(13) on the opposite side. Remove seal plate(3), O-ring(4) and wiper(3).

4. Hold the spool(2) in a vise using rigid wood pieces(Fig. 2-1) to prevent damage. Remove cap screw(8) and remove spring seat(7), spring(9), wiper(5) and O-ring(4). At this time, take care that the cap screw or other parts are not ejected out by the force of the spring(9)

The disassembled parts have to be arranged in order to identify their assembly position on work bench, shelf, etc.

Washing

Wash all the disassembled parts completely with mineral oil. Dry the washed parts with compressed air and arrange them on clean paper or cloth for inspection.

Inspection

Inspect all the parts if they have any burr, scratch, dent, or any other defect.

1. Confirm that the spool surfaces are free from scratch or dent. Small scratch can be removed with oil stone or cloth with lapping material.

2. Reciprocating parts must move smoothly. All the holes and paths must be free from foreign matter.

3. Worn, deformed, or broken spring must be replaced.

4. Check that the sealing face of the valve housing is smooth, free from dust, rust, or dent.

5. Remove any dent or scratch on the check valve seat of valve housing by lapping. Take care not to leave any lapping material in the valve.

6. If relief valve is not in normal order, inspect it in compliance with the Relief Valve Maintenance Manual.

7. Replace all the O-rings and back-up rings with new ones.

8. Check that there is no residual coating debris around the housing holes and plug seats. In the event that coating debris is in the valve, it will cause malfunction and oil leak.

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