Related Manuals for Doosan D15S-5
Summary of Contents for Doosan D15S-5
- Page 1 SB4365E01 June. 2011 Vehicle System Specification Systems Operation Testing & Adjusting D15S-5, D18S-5, D20SC-5 G15S-5, G18S-5, G20SC-5 GC15S-5, GC18S-5, GC20SC-5...
- 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.
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Page 5: Table Of Contents
Index Steering Unit ............36 Brake System ............38 Master Cylinder ..........38 Specification ..........5 Shoe Type Brakes ..........39 Parking Brake ............. 39 Control Valve ............5 Hydraulic Pump ............6 Testing and Adjusting ......41 Sideshift Cylinder ............6 Lift Cylinders ............. -
Page 7: Specification
Specification Control Valve CONTROL VALVE RELIEF PRESSURE MODEL MAST Main Relief Pressure-lift Auxiliary Pressure-tilt,attachment D15S,G(C)15S-5 STD/FF/FFT 2,550±35 17,600±250 D18S,G(C)18S-5 STD/FF/FFT 2,880±35 19,860±250 2,040±50 14,000±350 D20SC,G20SC-5 STD/FF/FFT 3,125±35 21,550±250 (1) Torque for nuts that hold control valve sections together ......... 24 to 28 N•m (18 to 21 lb•ft) (2) Torque for nuts that hold control valve sections together ......... -
Page 8: Hydraulic Pump
Hydraulic Pump Sideshift Cylinder (1) Torque for head .......270±35 N•m Rotation is counterclockwise when seen from drive (200±25 lb•ft) end. Type of pump : Gear (2) Torque for piston nut ......260±25 N•m For test, use SAE 10W oil at 65°C (150°F) (190±20 lb•ft) Pump output....19.5 cm³/rev (1.19 in³/rev) Vehicle Systems... -
Page 9: Lift Cylinders
Full Free Triple and Full Free Lift Lift Cylinders Primary Standard (1) Put Pipe Sealant on the last three threads of (1) Put Pipe Sealant on the last three threads of bearing. bleed screw and tighten to a torque of ... 6±1N•m (53±9 lb•in) (2) Put Pipe Sealant of the last three threads of bleed screw (not shown) and tighten to a torque... -
Page 10: Full Free Lift Secondary
Full Free Lift Secondary Full Free Triple Lift Secondary (1) Put Pipe Sealant on the last three threads of (1) Put Pipe Sealant on the last three thread of bearing. bearing. (2) Put Pipe Sealant on the last three threads of (2) Put Pipe Sealant on the last three thread of bleed bleed screw and tighten to a torque of .... -
Page 11: Tilt Cylinder
Tilt Cylinder Truck Model Forward Backward Closed Length Stroke Cylinder P/No. 6° 10° 372.5 mm 82 mm D518277 DG15/18S-5 8° 10° 372.5 mm 91.5 mm 400334-00015 6° 10° 392.5 mm 73 mm D518224 GC15/18S-5 6° 10° 392.5 mm 82 mm A252107 (1) Adjust pivot eye to dimension(Y) with cylinder open (extended) -
Page 12: Steering Wheel
Steering Wheel Priority Valve (1) Torque for steering wheel nut ..75 to 88 N•m Flow ............Load sensing (55 to 65 lb•in) Relief valve (no adjustment) opens at: ........ 8,285±350 kPa (1,200±50 psi) Vehicle Systems Specifications... -
Page 13: Steering Unit
Steering Unit (1) Pin (1) in the body must be aligned with internal pump gear (gerotor) (2) and drive (3) as shown. (4) Tighten bolts in sequence shown. Tighten to a first torque of ..... 14.1±2.8 N•m (125±25 lb•in) Tighten to a final torque of .... 28.2±2.8 N•m (250±25 lb•in) (5) Torque for plug .... -
Page 14: Forward And Reverse Control Group
Forward and Reverse Control Brake – SHOE Group (1) Torque for wheel cylinder bolts (1) ... 8 to 12 N•m (6 to 9 lb•in) (1) Torque for bolts (four)....3.4 to 3.9 N•m (30 to 34.5 lb•in) (2) Torque for bolts (two) ....2.8 to 3.4 N•m (25 to 30 lb•in) Vehicle Systems Specifications... -
Page 15: Delayed Engine Shutdown System
Delayed Engine Shutdown System Operation The delayed engine shutdown system will shut the engine down if no proper action is taken by the operator. This system makes use of the engine oil pressure switch, transmission oil temperature switch and water (coolant) temperature sensor to the required truck condition. -
Page 16: Diagram Of Delayed Engine Shutdown System
Diagram of Delayed Engine Shutdown System G424I(E) / G424F(E) ENGINE – LP TRUCK G424I(E) / G424F(E) ENGINE – GAS & DF TRUCK Vehicle Systems Specifications... -
Page 17: Trouble Shooting Of Delayed Engine Shutdown System
Trouble shooting of Delayed Engine Shutdown System When the ignition key is turned on, the MIL Lamp will illuminate and remain on until the engine is started. Once the engine is started, the MIL Lamp will go out unless one or more fault conditions are present. If a detected fault condition exists, the fault or faults will be stored in the memory of the small engine control module (SECM). -
Page 18: Delayed Engine Shutdown System Schematic
Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN : G424I(E) - LP Vehicle Systems Specifications... -
Page 19: Delayed Engine Shutdown System Schematic
Delayed Engine Shutdown System Schematic ENG GND NEAR COILS E/G OIL PR E/G CHECK DELAYED ENGINE SHUTDOWN : G424I(E) - GAS&DF Vehicle Systems Specifications... - Page 20 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN : G424F(E) - LP Vehicle Systems Specifications...
- Page 21 Delayed Engine Shutdown System Schematic DELAYED ENGINE SHUTDOWN : G424F(E) - GAS&DF Vehicle Systems Specifications...
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Page 22: Oss (Operator Sensing System)
OSS (Operator Sensing System) Operation 4. Water separator (sediment) warning – only diesel Water separator lamp indicates when the engine Operator Sensing System is operated by seat switch is running and there is much water in the fuel filter built into the seat. If the operator leaves the seat exceeding 100cc. -
Page 23: Operator Sensing System Schematic
Operator Sensing System Schematic Vehicle Systems Specifications... -
Page 24: Trouble Shooting Of Operator Sensing System
Trouble shooting of Operator Sensing System CONDITION PROBABLE FAULT CORRECTIVE ACTION 1. Buzzer warning 1. Seat switch open 1. Check seat switch 2. Parking brake 2. Parking brake switch open 2. Check parking brake switch light 3. Controller defect 3. Check continuity of wire from seat switch to controller (SW2) 4. - Page 25 CONDITION PROBABLE FAULT CORRECTIVE ACTION 1. Buzzer 1. Seat switch open 1. Check seat switch warning 2. Fift lock / Unload 2. Check Lift lock/Unload Solenoid 2. Mast interrupt solenoid defect light 3. Check continuity of wire from solenoid-lift lock(2) or 3.
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Page 26: Hydraulic System Operation
Hydraulic System Operation Hydraulic Schematic Basic Hydraulic Actuator System Schematic (1) lift cylinder secondary, standard (2) flow protector-primary (3) lift cylinder-primary (4) flow protector-secondary, standard (5) side shift cylinder (6) control valve (7) solenoid valve for lift lock (8) tilt cylinder (9) relief valve-auxiliary (10) solenoid valve for unload (11) relief valve-main (12) hydraulic pump (13) hydraulic tank (14) filter-return (15) priority valve... - Page 27 The hydraulic system has a hydraulic tank (13) The relief valve-main (11) releases the excessive which holds a fluid for a hydraulic pump (12). A pressure to the hydraulic tank when the pressure in hydraulic pump sends a pressure fluid to the the lift circuit goes higher than a setting pressure hydraulic actuator system and hydraulic steering shown...
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Page 28: Control Valve
Control Valve External View 4 – Spool I.C Truck Valve Circuit Schematic 4 – Spool I.C Truck Valve Vehicle Systems Systems Operation... -
Page 29: Inlet Section
Inlet Section • The inlet section contains the pump inlet connection as well as a diagnostic inlet pressure gage port (new feature to be added). • When the operator is not seated, the solenoid valve is in the normally open position, which helps divert flow from the pump directly to the outlet of tank. -
Page 30: Lift Section
Lift Section • The lift section has a single work port to direct flow to the lift cylinder is single-acting (gravity returns the mast to the lowered position). • The lift section also contains part of the components which comprise the ISO safety features. There is a normally closed solenoid valve that works in conjunction with a lift lock check valve. - Page 31 • Lowering: When the seated operator shifts the lever forward, the spool retracts into the valve, and the oil is directed from the cylinder, past the lift lock check valve, past the pool metering notches, and to the common tank cavity. •...
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Page 32: Tilt Section
Tilt Section TILT LOCK PLUNGER • The tilt spool contains an internal plunger which acts to stop tilt forward actuation when the battery power is off. • Tilt Forward: When the seated operator shifts the lever forward, pressure is applied to the head of the tilt cylinder, and the forks tilt forward. -
Page 33: Auxiliary Section
Auxiliary Section • In general, one work port is pressurized by high pressure oil from the parallel passage past the load check valve, past the metering notches, and to the cylinder. Simultaneously, oil from the other work port is directed across the spool metering notches to tank. Vehicle Systems Hydraulic System Operation... -
Page 34: Outlet Section
Outlet Section • The outlet section contains the tank port and the secondary relief valve (with built-in anti-cavitation feature). Vehicle Systems Hydraulic System Operation... -
Page 35: Relief Valve
Relief Valve If the control lever is held in LIFT or TILT position after the cylinder rod is fully extended or retracted, the flow of oil from outlet port to the cylinders is stopped. The oil under pressure must be released. The pressure oil flows through piston (11) of the main relief valve. -
Page 36: Hydraulic Steering System
Hydraulic Steering system Hydraulic Schematic steering system schematic (1) steering unit (2) hydraulic line (3) hydraulic line (4) hydraulic line (5) hydraulic line (6) power steering cylinder (7) hydraulic line (8) pump motor (9) hydraulic line (10) hydraulic pump (11) hydraulic tank (12) priority valve (13) suction filter (14) filter-return (15) hydraulic line (16)hydraulic line The steering system uses the hydraulic fluid for During a right turn, pilot pressure is increased in... -
Page 37: Steering Cylinder
Steering Cylinder During a left turn, a pilot pressure is again increased in load sensing line(7) which moves the spool of priority valve to the right. A fluid flows through a Steering cylinder (1) gives power assistance through hydraulic line(9) to a steering unit. From the steering the use of pressure oil at either end of the cylinder. -
Page 38: Steering Unit
Steering Unit Steering Gear (1) Spool. (2) Sleeve. (3) Outlet (to tank). (4) Inlet (for pump oil). (5) Internal pump gear. (6) External pump gear. (7) Centering springs. (8) Pin. (9) Left turn port. (10) Right turn port. (11) Body. (12) Drive. (A) Control section. (B) Metering section. Oil from the priority valve goes through inlet (4) into Lift trucks use the load sensing, closed center (oil the control section of the steering unit. - Page 39 Oil Flow The oil from the priority valve flows through inlet (4). When the steering wheel is stationary (NEUTRAL), the oil is stopped by spool (1). The oil can not flow through the steering unit to the steering cylinder until the steering wheel is turned.
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Page 40: Brake System
Brake System Brake fluid from remote reservoir (1) to replenish master cylinder (2). Master Cylinder The master cylinder has a piston which pushes brake liquid into the brake lines. The reservoir, located on the cowl, is connected to inlet of master cylinder. -
Page 41: Shoe Type Brakes
Shoe Type Brakes Automatic Adjustment Brakes with automatic adjustment are adjusted on the reverse braking action. In this example the drum rotation is counterclockwise (in reverse) which causes a counterclockwise rotation of the brake shoes. Secondary shoe (4) moves away from cylinder (2) that causes link (1) to move toggle lever (6) in a clockwise rotation. - Page 42 Adjustment Procedure : 1. Put the parking brake control lever in the released position. 2. Bend lock (5) away from nut (6). Adjust nut (6) so lever (4) is against stop (3). 3. Tighten nut (6) finger tight and bend lock (5) to hold in place.
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Page 43: Testing And Adjusting
2. Remove the filter element and look for particles Testing and Adjusting removed from the oil by the filter element. A magnet will separate ferrous particles from non Troubleshooting ferrous particles(piston rings, O-ring, etc). 3. Check all oil lines and connections for damage or Troubleshooting can be difficult. -
Page 44: Hydraulic System And Mast
NOTE : If the problem is because of air in the oil, It must be corrected before the system will 2. The relief valve opened at low oil pressure. operate at normal temperatures. There are two things that cause air in the oil (aeration). 3. - Page 45 3. Damaged cylinders. Probable Mechanical Cause: Probable Mechanical Cause: 1. The mast is not in alignment with the other lifting components and does not move freely. 1. Not enough lubricant on the parts of the mast that 2. Carriage chains need an adjustment. move.
- Page 46 Problem: Safety lift lock doesn’t work WARNING Safety lift lock function: Once the operator leaves a seat more than 3 seconds or a start key is off, the lift First of all, the needle valve in control valve as cylinder doesn’t lower, even though lift spool is seen in a picture below should be loosened with pulled for lowering.
- Page 47 Problem: The oil temperature is too high. 5. The pump has too much wear. Probable Cause: 6. Failure of the pump shaft or coupling. 1. The oil level is low. 7. The bolts of the pump do not have the correct torque.
- Page 48 Problem: The load lowers when the lift spool is Lift and Tilt Cylinders moved from the NEUTRAL position to the RAISE position. Problem: Leakage around the piston rod. Probable Cause: Probable Cause: 1. There is foreign material in the load check valve 1.
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Page 49: Steering System
Steering System Problem: Low oil pressure. Problem: Too much force needed to turn Probable Cause: steering wheel. 1. Low oil level. Probable Cause: 2. Priority valve relief valve spring weak. 1. Priority valve releases pressure oil at a low setting. 3. -
Page 50: Brake System
Problem: The temperature of the oil is too hot. Problem: Pedal resistance is not solid (spongy). Probable Cause: Probable Cause: 1. The viscosity of the oil is wrong. 1. Leakage or low fluid level. 2. Air mixed with the oil. 2. - Page 51 Problem: Brake will not make application. Probable Cause: 1. Leakage or low fluid level. 2. Lining surface looks like glass (glazed), or worn. 3. Oil or brake fluid is on the lining. 4. Air in the brake hydraulic system. 5. Bad master cylinder. 6.
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Page 52: Lift Cylinders Air Removal
Lift Cylinders Air Removal After the lift cylinder has been disassembled and then assembled again, it may be necessary to remove the air (bleed) from the cylinder. 1. With no load, lift and lower the mast and carriage through one complete cycle. 2. -
Page 53: Hydraulic System
Hydraulic System Relief Valve Pressure Check Use the pressure Gauge kit to check the relief valve pressure. WARNING Hydraulic oil, under pressure can remain in the hydraulic system after the engine and pump have been stopped. Personal injury can be caused if this pressure is not released before any work is done on the hydraulic system. -
Page 54: Lift Relief Valve Check And Adjusment
Lift Relief Valve Check and Adjusment 1. Turn the key switch on and activate the hydraulics until the hydraulic oil is at the normal operating temperature. 2. With the engine at fast rpm under unload condition, hold the lift control lever in the lift up position and watch the gauge. -
Page 55: Tilt And Auxiliary Relief Valve Check And Adjusment
Tilt and Auxiliary Relief Valve Check and Steering System Adjusment Steer Wheel Bearing Adjustment - 1. Turn the key switch on and activate the Pneumatic hydraulics until the hydraulic oil is at the normal operating temperature. Put the carriage in the full sideshift position. -
Page 56: Steer Axle Stop Adjustment-Pneumatic
Steer Axle Stop Adjustment-Pneumatic Steer Wheel Bearing Adjustment- Cushion Steer Axle End. (1) Bolt (2) Nut (A) 80°angle Use the procedure that follows to make an Bearing Adjustment adjustment to the steer axle turning angle. Nut. (2) Lock. 1. Adjust the cylinder rod extension so it is equal on both sides of the axle. -
Page 57: Steer Axle Stop Adjustment-Cushion
Steer Axle Stop Adjustment-Cushion 2. Loosen nut (5) and (4) on steer axle ends. Turn setscrew (8) and (3) all the way in. Put right steer knuckle in forward cramp until steering cylinder internal stop is reached. Adjust setscrew (6) of right end of steer axle and setscrew (3) of left end of steer to contact steer knuckle. -
Page 58: Steering System Pressure Check
NOTE: The oil in the lines to the steering cylinder Check steering system relief pressure as stops at the piston. The oil in the cylinder does not follows: flow in a circuit. As the piston moves backward and forward, the oil moves backward and forward in the 1. - Page 59 NOTICE Do not let valve be closed for more than 3 or 4 seconds or damage can be caused to the steering system components. a. With the engine running, turn the steer wheels in any directions and read the indication on pressure gauge (6).
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Page 60: Brake System
Pedal Adjustment for Brake & Inching Brake System Brake System Air Removal The adjusting procedure is as follows. Be sure that the air bleeding of brake system should be done in Systems With Remote Reservoir advance. Remote Reservoir Location 1. Adjust the length (A) from the spool to the (1) Remote reservoir. - Page 61 5. The distance (E) between the shaft center and its mounting bracket should be 82.5mm. 3. Adjust the height (C) of inching pedal and brake pedal. (C) should be 101 ± 1mm at the same level. 6. The stroke of inching spool should be 8 ± 1mm. 7.
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Page 62: Parking Brake Test
Parking Brake Test Parking Brake Adjustment WARNING To prevent personal injury, the operator must be ready to use the service brake if the parking brake is not adjusted correctly and the lift truck starts to move. 1. Drive the fully loaded lift truck up a 15% incline. 2. - Page 63 5. Loosen nut (2). 6. Tighten screw (1) to a torque of 5.6 to 6.8 N·m (50 to 60 lb·in). 7. Loosen screw (1) 1.2 to 1.5 turns, hold in this position and tighten nut (2). IDCS219S Parking Brake Adjustment (7) Switch Assembly.
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